CHAPTER 5CHAPTER 5

Protective Packaging and Protective Packaging and Materials HandlingMaterials Handling

5-2

Learning Objectives

To know how product features affect packaging and materials handling

To identify the functions performed by protective packaging

To analyze the utilization of unit loads in materials handling

5-3

Learning Objectives

To appreciate how the environmental protection movement has affected packaging and package choice

To learn materials handling principles

5-4

Protective Packaging and Materials Handling

Key Terms

Building-blocks concept

Bulk materials Compliance

labeling

Key Terms

Ergonomics Materials

handling Package testing

5-5

Protective Packaging and Materials Handling

Key Terms

Pallets Recycled content Slip sheet

Key Terms

Unitization Unit loads

5-6

Product Characteristics Physical Characteristics

Density of bulk materials Ability to withstand exposure to elements Respiration

Chemical Characteristics Incompatible products Products requiring chemicals

Characteristics must be made known to consumers

5-7

Figure 5-1: Portion of Fabric

Care Label for Levi’s Jeans

Sold in Japan

5-8

Product Characteristics Hazardous Cargo

Explosives Compressed gases Flammable liquids Oxidizers Poisons Radioactive materials Corrosive materials

5-9

Product Characteristics Environmental Protection

Reduce packing materials used Use packaging materials that are more

environmentally friendly with recycled content Use reusable containers Retain or support services that collect used packaging

and recycle it

5-10

Product Characteristics Packaging Scrap Disposal

Pallet shredder

Metric System usage

5-11

Figure 5-3: A Pallet Shredder Designed

to Reduce the Cubic Volume of

Wooden Pallets and Crating So That

They Cost Less to Transport

5-12

Packaging Building-blocks concept

Smallest unit is consumer package Each unit is stocked within the next larger one to

protect the product

Promotional functions of boxes

5-13

Packaging Protective functions of packaging

Enclose materials Restrain materials from undesired movement Separate contents to prevent undesired contact Cushion contents from outside vibrations and shocks Support the weight of identical containers stacked above Position the contents to provide maximum protection Provide for uniform weight distribution Provide exterior surface for labeling Be tamperproof Be safe for consumers or others

5-14

Figure 5-7: Checklist for

Box Users

5-15

Figure 5-9: Boxmaker’s Certificate

(BMC)

5-16

Packaging Package testing

Vibrations Dropping Horizontal impacts Compression Overexposure to extreme temperatures or moisture Rough handling

5-17

Figure 5-10: Results of

Compression Test

5-18

Packaging A package system requires 3 types of

information to design Severity of the distribution environment Fragility of the product Performance characteristics of various cushion

materials

5-19

Packaging Labeling

Retroflective labels Batch numbers Weight Specific contents Instructions for use Information to allow passage through customs Compliance labeling One- or two-dimensional bar codes Smart labels or RFID labels

5-20

Figure 5-14: Examples of

Shipping Labels

5-21

Figure 5-16: A Handheld Laser Scanner Scanning

Labels on a Pallet Load of Product Sitting in a

Warehouse Rack

5-22

Unit Loads in Materials Handling

Basic unit is a pallet or skid Lumber is expensive so firms want pallets

returned Provides cushioning effect in transport Quality of pallets varies widely Chep USA rents pallets in wood or plastic Should be less than 50 pounds—difficult with

plastic Metal also used in closed loop systems

5-23

Unit Loads in Materials Handling

A unit load is one or more boxes secured to a pallet or skid so that boxes can be handled by mechanical means

Rainbow pallet load Unitization describes this type of handling Slip sheet can be used in place of pallet

Saves vertical room Requires more care when moving

5-24

Unit Loads in Materials Handling

Advantages Additional protection Pilferage is discouraged More fragile items can be

stacked inside the load Mechanical devices can

be substituted for hand labor

Disadvantages Provides large quantity

that sometimes is of limited value to resellers dealing in smaller quantities

Must use mechanical or automated device to move

5-25

Figure 5-19: A Battery Powered Lift Truck Used for Stock

Picking

5-26

Unit Loads in Materials Handling

An intermodal container holds the unit load Interchangeable among rail, truck, and water

carriers Air carriers usually use irregular shaped

containers made to fit fuselage

5-27

Figure 5-21: Various Types of

Intermodal Surface

Containers

5-28

Unit Loads in Materials Handling

Equipment loading Load-planning Bracing Inflatable dunnage bags Load is subjected to five forces

Vibration Centrifugal Retardation Roll Pitch

5-29

Figure 15-25: The Building-Blocks

Concept of Packaging: A

Summary

5-30

Materials Handling

Materials handling refers to how the materials or products are handled physically.

How the products are handled depends on whether they are packaged or in bulk

Handling may change the characteristics of the product

5-31

Materials Handling Principles

Orientation Requirements Integrated system Standardization Just-in-time Unit load

Minimum travel Space utilization Ergonomics Energy Ecology Mechanization

5-32

Materials Handling Principles

Automation Flexibility Simplification Gravity Safety Computerization

Systems flow Layout Cost Maintenance Obsolescence Team solution

5-33

Materials Handling in the Supply Chain

Products can move throughout the entire supply chain

Bar codes, two-dimension codes, radio-frequency codes systems facilitate integration throughout the supply chain