How a repair request led to an award-winning new packaging solution
Safran turned to Antalis to repair worn steel transit cases used to transport aircraft landing gear parts between the UK and France. But after assessing the cases in use, our packaging experts identified an opportunity to create something far more effective: a durable, repairable and more efficient bespoke transport solution.
Safran turned to Antalis to repair worn steel transit cases used to transport aircraft landing gear parts between the UK and France. But after assessing the cases in use, our packaging experts identified an opportunity to create something far more effective: a durable, repairable and more efficient bespoke transport solution.
The client’s challenge
Safran, the world’s largest landing gear manufacturer, was using large steel transit cases that had become worn and corroded through repeated use. As well as being heavy and difficult to manoeuvre, the cases increased risk to the parts being transported.
The current solution
While the original brief was to repair the existing cases, the project quickly evolved into a full redesign of the packaging solution. The new design needed to:
- Offer greater durability for frequent freight shipping
- Protect both the storage system and the parts being transported
- Reduce the overall size and weight of the cases
- Meet strict health and safety requirements
These requirements included a truck stop (hand brake), heavy-duty wheels with locks, nylon bar shock absorbers, cups for safe stacking, and forklift access built into the base.
The Antalis solution
Antalis developed a fully reverse-engineered transport system, designing the packaging around the parts to optimise protection, handling and presentation.
The final solution was a compact, stackable dual-case system comprising:
- A 5-tier drawer-based case.
- A single-item case capable of carrying a part weighing up to 150kg.
Constructed using 12mm plywood with an internal aluminium frame, the new design is smaller, lighter and more weather-resistant than the original steel cases.
To further improve usability and efficiency, the solution also includes:
- Numbered drawers that correspond with the order of part assembly.
- Colour-coded and labelled foam inserts to support part identification.
- Individually removable and replaceable foam inserts if damaged.
- Lockable drawers to help protect parts in transit.
A smarter approach from concept to implementation
What began as a repair request became an opportunity to rethink the entire transit process. Working closely with Safran, our Antalis packaging team followed a clear four-stage approach to deliver a more durable and efficient result.
Explore
Our team visited Safran’s facility to inspect the existing cases in use and observe how they were stored, handled and transported. It was immediately clear that the steel cases were corroded, damaged, heavy and difficult to manoeuvre.
Propose
Rather than simply repair the cases, Antalis proposed a fully reverse-engineered design built around the parts themselves. A colour-coded drawer-based system with labelled sections was developed to improve presentation and make loading and unloading easier.
Test
The solution was refined in collaboration with Safran teams across different management levels. Two prototype case designs were produced: a 5-tier drawer system and a single-item case capable of holding parts weighing up to 150kg.
Implement
Following acceptance of the proposal and prototypes, 48 cases were manufactured and are now in active use transporting landing gear parts for Boeing and Airbus aircraft.
Result: a durable, repairable and more efficient transport system
The new flight case solution has improved part protection, reduced transport costs and made handling easier for engineering teams. It has also reduced waste by allowing damaged elements to be replaced individually rather than replacing the full case.
Advantages of the solution
Cost savings
£12k per month reduction in transport costs.
Repairable
Damaged panels and foam inserts can be replaced individually without replacing the full flight case.
Efficiency
A lighter, more compact and stackable design improves space saving and ease of movement.
Improved part identification
Numbered drawers, clear labelling and colour-coded inserts make parts quicker and easier for engineers to identify.
Sustainability
A 30% weight reduction improves manoeuvrability and helps reduce transport costs.
“This project is a great example of how the right packaging and know-how can make a big difference in all kinds of ways. The initial requirement was simply to repair existing cases, but we knew we could provide a much better solution, and we have. Durable, repairable, sustainable, and easier to use, the new flight cases have helped to improve operational efficiency, reduce costs, and cut environmental impact.”
— Jordanna Price, New Business Development Manager – Packaging, at Antalis
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