LOGISTICAL

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This blog is proudly prepared and presented by: *Wong Qian Hui (P02)
*Ng Kim Leong (P04)
*Chew Meng Wei (P05)
*Seah Yan Lin (P05)
*Tan Mei Jia Bella (P05)
*Ye Shuying (P05)

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{Monday, January 22, 2007 @ 1:11 PM}

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{Wednesday, January 17, 2007 @ 8:18 PM}

Introduction

Within a warehouse and while being transported throughout a logistics system, the package serves to identify and protect product. Its objective is to ensure that the product is protected from damage during delivery from the distribution centre to the customer's delivery location and that the product is received by the customer in satisfactory condition.

In the distribution business, the condition of a product's exterior package is the customer's first impression of the company's order-fulfillment service. This fact is especially true for catalog, e-commerce and direct mail business.

The package, containing a product, is the entity that must be moved by a firm's materials handling system. For this reason we will jointly discuss packaging and materials handling as integral parts of a warehousing and a firm's logistical system.

{Monday, January 15, 2007 @ 8:17 PM}

Numerous material types are used for logistics packaging, ranging from traditional corrugated cardboard to more exotic plastics. Traditional alternatives are reviewed first, followed by a discussion of emerging material alternatives.

{Sunday, January 14, 2007 @ 11:30 PM}

Corrugated Fibreboard Boxes

Advantages of fibreboard boxes:

Low weight and easy to handle.

The relatively soft walls have a cushioning effect.

The box can have any design, although it is recommended to use sizes fitting on the standard design of pallets.

The boxes are delivered flat and assembling boxes can be done locally.

The material can be printed to give the box a pleasant and recognisable appearance. Also the label can be included in this print.

Range of sizes and shapes and their availability

Inexpensive and can be easily manufactured, printed, and stored

Good impact strength

Disadvantages of fibreboard boxes:

Moisture and high humidity can seriously weaken the box. Washed produce should be dried before putting it into the box. Empty boxes should be stored in a dry place preferably flat on top of pallets and not for long periods of time. For certain commodities waxed carton boxes are preferred.

The low rigidity causes the stacking strength to be lower than for wooden or plastic crates. The fibreboard boxes are easily damaged by rough handling and ropes and too much weight on top of the box can crush the perishable produce inside.

Ventilation holes are usually small, because large holes would seriously influence the strength of the box. It is advised that the hole surfaces are at least 5 percent of the total box surface. Decreasing the size of the holes by not properly closing telescope boxes or not properly stacking the boxes will decrease heat exchange, resulting in higher temperatures of the produce and increased spoilage. Vertical oblong slots, instead of round holes, have the advantage that the hole stays partly open even when the telescope box lid is not completely closed.

The boxes are not re-usable.

Poor insulation

Features

Versatility

High strength and low weight characteristics

Product containment and Protection features

Ready adaption to a wide range of product techniques

Use of renewable resources and suitability for recycling and suitability for graphic design

The relatively soft walls have a cushioning effect. The box can have any design, although it is recommended to use sizes fitting on the standard design of pallets. The boxes are delivered flat and assembling boxes can be done locally.

Corrugated fibreboard boxes are manufactured in a similar manner to the solid fibreboard boxes but are made of a corrugated fibreboard sheet sandwiched between thin layers of coated solid fibreboard . Corrugated fibreboard boxes consists of 2 layers of cardboard called ‘liners’ and a corrugated central part called ‘’fluting’’. The liner is manufactured from long fibres in order to make it strong and hard-wearing. The fluting is manufactured from short fibres in order to make it stiff and resistant to pressure. This fantastic construction forms rows of stiff waves capable of sustaining large weight.

Durability

The strength of corrugated fibreboard is determined by the type of fluting material, the type of facing material and its thickness and a single or double wall. Fluting and facings are kept in place by water resistant glue. New box designs are usually tested for bursting strength, puncture strength, flat crush strength and edge crush (stacking) strength. Strong quality corrugated cardboard boxes may easily be stacked on top of each other and are very pressure and push resistant both at the sides as well as the top. Heavy duty corrugated cardboard boxes may endure falling, vibrations, temperature fluctuations, moisture and even being subjected to water at the bottom for many hours without damage to the cardboard.

Functions

Corrugated fibreboard boxes also known as cardboard boxes are used for packaging commercial goods or storing goods and materials. Corrugated cardboard can be cut and folded in infinite sizes and shapes. It is also possible to print on corrugated cardboard and as a consequence the packaging may serve both as a protection of goods as well as an advertisement display.

Practices

Positioning

Store boxes flat from the time they are received until they are ready for use. (Damage to the edges of boxes can occur if they are stored on edge, which can affect runnability on automatic equipment, closure and product protection.)

Stability in storage

Leave the strapping, bundling or other unitizing device in place until boxes are ready for use

Alternate bundle direction or alternate loose boxes at intervals for greater stability.

Avoid stacking boxes too high whether loose or banded because of slight instability of stack. (Although close, most boxes are not totally flat. The extra thickness of the tab used at the joint adds a bulge, usually near the centre, giving a tilt to a loose stack of boxes. Alternating directions of bundles when stacking compensates for the tilt and increases stability.

Crushing and puncture

When building pallet loads of flat boxes, use deck boards to distribute weight evenly

Stack boxes only on smooth, clean surfaces

Use good materials handling procedures, do not drop or throw bundles or pallets into place

Don’t stand, sit or climb on stacked boxes, or place heavy objects on them(This may crush or distort the flutes in corrugated boxes which will reduce their protective abilities. Any uneven pressure on the flutes can cause crushing or puncture.)

Storage Environment

Store boxes on the floor, on pallets or other flat dunnage

Store boxes indoors and protect them from overhead moisture

Avoid temperature and humidity extremes and fluctuations in storage area

{ @ 10:30 PM}

Corrugated Fibreboard Storage Bins

Features

Economical storage solution

Supplied flat packed for easy assembly

Extensive range of bin & box sizes available

Can be stacked on top of each other while still allowing access to contents

{ @ 9:56 PM}

Packaging practices

Adding a fiberboard divider to a carton will increase stacking strength. The use of dividers is common with heavy crops such as melons. The dividers also prevent melons from vibrating against one another during handling and transport. Wooden inserts, or fiberboard folded into triangles and placed in all four corners can be especially useful when a carton needs strengthening.

Fiberboard divider:

Triangular corner supports:

When locally made containers have sharp edges or rough inner surfaces, a simple, inexpensiveinner made from fiberboard can be used to protect produce from damage during handling.

Cardboard liner for a palm rib crate:

If large bags or baskets must be used for bulk packaging of fruits or vegetables, the use of a simple vent can help reduce the buildup of heat as the product respires. In the illustration below, a tube of woven bamboo (about one meter long) is used to vent a large bag of chili peppers.

Thin paper or plastic sleeves are a useful material for protecting cut flowers from damage during handling and transport. In the illustration below, a packer is pulling a sleeve up over a bunch of flowers before packing the flowers into a vented fibreboard carton. The sleeves both provide protection and help keep the bunches of flowers separate inside the box.

{ @ 9:00 PM}

Corrugated Box Styles

Regular Slotted Containers- RSC

All flaps same length. Outer flaps meet. Regular Slotted Boxes are in more general use than any other style because they are the most economical to manufactures and use.

All Flaps Meet-AFM

Inner and outer flaps meet at the center. Similar to a regular slotted box except that is the stronger at the top and bottom due to the double thickness of corrugated board in these areas.

Partial Overlap Slotted Container-POL

All flaps same length. Outer flaps overlap-specified amount but not less than 1 inch. The inner flaps do not meet. The box is easily closed, usually with staples driven through the overlap area.

Full Overlap slotted Container-FOL

All flap same length. Outer flaps overlap not less than inside width of box minus a maximum of 1 inch. When this style box is stacked on its side panel, the extra thickness of corrugated board on the top and bottom panels provide stacking strength. The outer flaps, which almost completely overlap, making this box unusually resistant to rough handling.

{ @ 8:54 PM}

How to measure Corrugated boxes

Box Dimensions

Box dimensions are always Inside dimensions and must be stated in the sequence of length, width and depth. Even when the box is to have interior packing, the dimensions given should be the inside dimensions of the box irrespective of the interior packing. The length is the larger of the two dimensions of the open face (flap opening); the width is the smaller. The depth is always the distance measured perpendicular to the length and the width between the innermost surfaces of the box.

Even so-called "end o-opening" or "end-loading" boxes follow the above principles. Thus, the depth is still the dimensions between the innermost surfaces of the box measured perpendicular to the length and width.

A tight fit is important for safe transportation and the box manufacturer is better able to design a box of the proper size if he is furnished with a sample of the article to be packed. If it is not practicable to submit a sample, a complete description of the article, including drawings when available, the quantity to be packed, and the weight to be shipped in the box should be supplied to insure that the box which is designed will comply with the carriers specifications.

To properly measure a corrugated box, score to score measurements should be taken for each dimension. Since, when describing a corrugated box the inside dimensions (or usable carton capacity) is considered, predetermined deduction from score to score measurements must be made to arrive at the true box size. Board flute, being of variable thickness, requires that each flute have there own set of score to score measurement deductions, as follows:

{ @ 8:40 PM}

Stainless Steel Drums

Stainless Steel drums are corrosion resistant and can be used for storage and/or shipping of foods and chemicals.

Stainless steel Economy drums are a good choice for acids, chemicals, pharmaceuticals, foods, and fragrances. They are lower in cost and can be reused.Seamless stainless steel drums are crevice-free to maximize protection against residue entrapment. These drums can be cleaned by simply washing. These drums are designed for use with nitric acid along with many other products.Open head stainless steel process drums are recommended for products such as food, pharmaceuticals, and other products which require high purity and sanitation. They have straight sides for complete emptying and easy cleaning.

Steel Drums Specifications

Size Range: 35 litres to 220 litres, 9 to 49 Imperial gallons

Steel:16 to 28 gauge

Construction: Double seamed or triple seamed ends. Bodies with expansions for rolling hoops, or straight sided.

Open Head Closures:Ring and Bolt, Lever Lock , Forged Lug

Gaskets: Flowed-in, sponge rubber, cotton, neoprene

Fittings: Wide range of 2" and 3/4" flanges and bungs, Rieke or Trisure, steel or plastic.

Linings: Clear Epoxy, Clear Phenolic, Pigmented Epoxy Phenolic, Pigmented Phenolic, plus custom linings for special requirements

Plastic Inserts: Polyliners in 4 mil. and 8 mil

Decoration: Painting or silkscreening to your specification.Embossing, serial numbering

Benefits of Steel Drums

Track Record: The new steel drum is a proven performer, backed by over 85 years of dependable and economical service around the world. Steel drums are authorized for a wider range of commodities and modes of transportation than competitive containers, thus providing unparalleled packaging and shipping versatility.

Safety: No other shipping container surpasses new steel drums in the safe transportation of hazardous materials. Specification drums are rigorously tested by the manufacturer to meet exacting requirements

Reusable: New Steel Drums are readily saleable for re-use and are recyclable through reconditioning services located across Canada

Strength: No other shipping container equals the new steel drum for ruggedness. Steel has exceptional tensile, tear and sheer strength

Product Protection: New Steel Drums provide excellent resistance to puncture, shock, cutting and abrasion. Special interior protective coatings ensure compatibility with your product
Cost Savings: Steel Drums can be stacked higher in storage thus saving valuable warehouse floor space. They can also be stored for longer periods of time without risk of distortion or failure.

Temperature Resistance: Steel is immune to extreme temperatures: "hot-fill" applications are problem-free. Dimensions, capacity, and container integrity are unaffected by the cold and sunlight or outside storage, or by repeated reconditioning.

{ @ 8:30 PM}

Burlap bags

Origin of burlap bags

Jute, the Golden Fibre, is a gift of nature to mankind. It is a cultivated vegetable fibre annually grown in the Eastern part in the sub-continent of Indian. The fibres obtained from the stalks of the jute plant are dried in the sun, pressed into bales and taken to the factories where it is spun into jute yarn. Jute is biodegradable and therefore environmentally safe. It decomposes and mixes with the soil and does not release toxic gases when burnt or destroyed unlike plastic or polyurethane which do not decompose, hence are to be recycled or destroyed resulting in pollution and waste of natural resources. As other materials like paper & cotton, jute can be recycled also. The jute cloth is then used and sewn into burlap bags.
Introduction of Burlap bags

Burlap is a dense woven fabric, usually made of jute and allied vegetable fibers. It is sometimes called Hessian cloth or sack cloth. It is sown during the rainy season in eastern countries such as India from March to May and harvested from June to September. Non-treated burlap has a light tan color.

The cloth is made in different width and weights, depending upon the use for which it is intended. The bags are tailored for packing goods up to 60 kilograms of weight. These bags serve important purposes especially in geo-based industries and other industries such as construction and cement making. If cleaning is required, dry clean for best results.

7-ounce burlap is a lighter weight material, with fewer threads per square inch than 10-ounce. It is available in plain and treated burlap (nursery applications), in multiple sizes and widths in burlap rolls, bags, and squares.
The nature of this fabric is an uneven weave which gives its unusual effect. Due to its coarse texture, it is rarely used for apparel. However, in some towns in Louisiana, a whip called quoit is made from braiden burlap, with which to lash Mardi Gras participants.
Due to burlaps strength and durability, yet bio-degradability burlap bags can be used for a variety of applications. Some of the more common applications are sand bags, or burlap bags for parts, grain sack races or quality bags with jute draw strings for presentations.

Being eco friendly and biodegradable, hydrocarbon-free jute burlap bags are gaining a lot of popularity the world over for storing food commodities in the most healthy and non-toxic packing. Hydrocarbon-free Burlap is totally free from hydrocarbons and petroleum-based batching oils so as to pack and store agricultural commodities, without any fear of contamination. Food Grade items like cocoa, coffee beans and shelled nuts need natural and non-toxic material to retain their freshness, natural aroma and taste.

Burlap has many applications including, but not limited to:

Bags made of burlap for agricultural and industrial products

Balling roots and earth when transporting trees and shrubs

Windbreaks and tree wrap to protect small plant life

Ground cover to prevent erosion or promote seed germination

Road covers to protect cement during the curing process

Burlap bags are usually used to hold:

· Feed
· Cottonseed meal
· Flour
· Fertilizer
· Suger
· Rice
· Soya meal
· Seeds
· Beans
· Potatoes
· Grain
· Linseed meal
· Peanuts
· Chemicals
· Coffee
· Sand
· OnionTobacco

Key Benefits:

Strong

Durable

Economical

Water resistant

Rugged exterior

Bio-degradability

No constraints on size

Most desirable for rip-rap uses

Flexible packaging applications

Absorbs moisture, oil and grease while allowing air flow

Disadvantages:

· Rot and deteriorate evenly, thus causing problems if bags are broken while in use.
· Burlap is a dry product and is flammable

{ @ 8:17 PM}

Packaging for Materials Handling Efficiency

Packaging utility reflects how packaging impacts logistical productivity and efficiency. All logustical operations are affected by packaging utility -- from truck loading and warehouse picking productivity to transportation and storage cube utilization. Materials handling efficiency in all of these cases is significantly influenced by package design, unitization, and communication characteristics.

{ @ 8:16 PM}

Pallet pool

Practices
Pallet pools have been implemented as a way to overcome traditional problems of disposal and exchange. High-quality pallets are expensive and are difficult to retrieve once they leave the owner’s control. When transfer to an external organization occurs, warehouses routinely exchange poor quality pallets and keep the higher quality ones.

Pros
A pallet pool eliminates the setups between jobs and creates a queue of jobs to feed the machine and keep the spindle cutting.

Another advantage of a pallet pool is a reduced number of parts made for inventory.

Transporter’s benefits:
· Improved vehicle utilization
· Ends pallet exchange disputes
· Faster turnaround times

Manufacturer’s benefits:
· Consistent high quality pallets and containers
· Reduced pallet expense
· Reduced transportation costs
· Reduced product damage

Distributor’s benefits:
· Faster load/unloading
· Reduced product damage
· Reduced pallet expense
· Reduced disposal expenses
· Improved safety

Features
Pallet pools consist of several components. These include:
* A device to move pallets inside the system. This can be a chain-type carrier that moves all the pallets around the system at the same time like a small train. Or, it can be a device that rotates and extends to reach any pallet on a random or sequential basis. Another example is a rail-guided vehicle moving up and down the row of pallets, picking a new pallet or delivering a finished pallet.
* Some form of storage to hold the pallet in a known location. Without the ability to identify the location of a pallet, the transporter isn't able to pick up pallets or place them reliably.
* At least one station where an operator can load unfinished parts and remove finished parts.
* A cell controller that manages the movement of a pallet to and from machines, initiates the machining sequence for the parts on the pallet, and keeps records of pallet pool activity.

Durability
Probing cycles are relatively short

{ @ 8:15 PM}

Plastic Pallet

Practices

A pallet is a flat square shape structure that is created to hold goods.

The pallet will allow certain material handling equipments like mobile forklift, hand-pumped and hand-drawn jacks to move the goods around in a stable manner. Moving goods on pallets and with material handling equipments will reduce the muscle power needed as compared to traditionally hand carry. Goods will be placed on top of the pallet and will be secured by straps or stretch-wrapped plastic film. Plastic pallets have a longer life span as they could be reuse.

Pros

· In long run, plastic pallets are more cost effective as compare to wood pallet as plastic pallet is recyclable. This means fewer or no repair is require.

· It is said that the usage of plastic pallets are 10 times longer than wooden pallets which make it longer service life.

· Plastic pallets improve efficiencies due to standard dimensions and lack of broken boards

· Plastic pallets are unaffected by moisture, fat, acids, solvents, and chemicals. In case of accident, they will not absorb acids and alkalis that can affect the integrity of the pallet.

· Plastic pallets are also resistant to insects and disease.

· Fungi and mould growth and termites can not infest the pallets as plastic is not a favorable environment as compared to wood.

· Contamination that accumulated on the plastic pallets over a period of time could steam cleaned or washed to be removed.

· Plastic pallets are resistant to high-pressure water and steam which are suitable for pharmaceutical industry and food industry. This makes it more hygienic as compared to wooden pallets.

· Plastic pallets do not have sharp edges, splinters and nails which make handling safe. This will lower workers compensation claims

· Plastic pallets offer better stability no damaged or missing boards causing spills or falling stacks.

· Plastic pallets are lighter as compared to wooden pallet (an average plastic pallet weights 25-35 % less). This allows lesser energy used when transporting and is also an added advantage when transporting by aeroplane.

· Plastic pallets allow for greater utilization of warehouse space stability and higher stacking

· Plastic pallets could be store out doors and will not require protection against moisture as it is weather resistant.

· Weather resistant: Can be stored out of doors and does not require protection against moisture.

Types

Some of the plastic pallets are lightweight plastic pallets, nestable plastic pallets, rackable plastic pallets, stackable plastic pallets, export plastic.

Features

These are some of the various sizes that could be found in the market. Plastic pallets can be molded to accommodate specific industrial requirements; there are also different colors to choose from for easy identification

Dimensions:
a) 1,000 x 800mm
b) 1,200 x 800mm (European size)
c) 1,100 x 1,100mm (Japanese standard)
d) 1,200 x 1,000mm (industrial size)
e) 1,200 x 1,100mm
f) 1,200 x 1,200mm
g) 1,300x 1,100mm
h) 1,400 x 1,100mm
i) 1,400 x 1,200mm

Functions

Better product protection is present with the use of plastic pallets as there are no nails or broken boards to damage payload.

Damage Level

Damage level for plastic pallets is lower than wooden pallets.

Durability

Plastic pallets are more durability and can be reused. This means longer life and lower life-cycle costs.

{ @ 8:15 PM}

Totes (Rigid IBC)

Totes are in the category of rigid IBC (Intermediate Bulk Container). A standard tote design includes a high-density polyethylene bottle in a solid tubular reinforced steel cage. The polyethylene bottle will be attached with a tap or valve at the bottom and a lid at the top. The reinforced steel cage is attached to a 4 ways pallet base, which can be made from wood, steel or plastic. It is use to store and handle products that are at state of liquid.

Besides containing hazardous liquid, lubricant, etc, there are other ranges of products like edible oils, edible fats, fruit juices, natural rubber, synthetic rubber, non-hazardous chemicals (adhesives, resins, etc.), etc. All these other products’ demands increase, will increase the demand for the use for IBC.

Practices
People will fill the Totes with liquid from the top lid, and dispense the amount of liquid from the bottom via the valve or tap. These functions facilitate easy usage.

It can be stacked to 3 high, which facilitates storage.

With its 4 way pallet base, it can be fork lifted easily for transport.

Considerably light when it’s empty, manual labour is able to carry it around.

Main products being store are dangerous goods (DG), lubricants and chemicals. Usually filled with the same product after depleted, so do not need to wash or clean.

Pros
Totes are easy to use, transport and recycle. (As explained above)

As it is made to be robust, therefore, it would be durable in terms for storage, also in rough handling.

Using this packaging can be cost savings as Totes can be reused and durable. Addition, it can be stacked to 3 high as to have more efficient space usage. The capacity ranges from 450 litres to 3000 litres of liquid.

Since it is made from polyethylene and steel, most parts of Totes can be recycled, which is proven to be environment friendly. As more people are more concerned about being environment friendly, this added points to be an emerging trend in logistical packaging.

Jumbo Bags (Flexible IBC)

Jumbo Bag is under the category of flexible IBC. It has bod

y made of flexible material which cannot be handled by human labour when filled. It is also mainly be set to shipments of solid products that in form of powder, flake or granular form. It will be used when products does not require further packaging. Jumbo Bag has been designed to be lifted from the top by means of “lifting eyes” (A.K.A. lifting loops or straps).

Besides handling products like chemicals and constructions materials (cement, gravel, sand, etc.), it is been widely used for other products like food (sugar, salt, flour, etc.), pharmaceutical, plastics (resin, pellets, etc.), absorbent polymer, rubber, carbon black, refractories (abrasive grit, ceramics, etc.), agriculture (seeds, grain, etc.),specialty minerals and etc. The demand for the products will contribute to the increasing demand for flexible IBC.

Practices
When shipping by sea, Jumbo Bags are gang-loaded with up to 14 Bags on a spreader bar and shipped as break bulk.
Jumbo Bags are usually utilized without pallets, therefore reduce additional handling.

When Bags are used for hazardous products, the UN marking for the product must be printed on the container body.

The standard filled diameter of Jumbo Bags is 114cm to 121cm, designed to fit two across in a truck or a shipping container. They can be manufactured to meet specific requirements of the container users.

Pros
Jumbo Bag can be folded up flat and secured for shipment to the user.

The weight of a Jumbo Bag used to pack one metric ton of product weighs 3.6kg to 4.5kg. Therefore this created a very high product weight ratio, by using of light weight package to pack heavy weight products.

Cost of Jumbo Bags is competitive with other forms of packaging. Due to mainly it is being used without the pallet and it is used when there are no other needs for other packaging.

By utilizing without pallets, it helps to reduce additional handling.

{Wednesday, January 10, 2007 @ 10:48 PM}

Hope everyone who has browse through our blog will have a greater understanding on how exaclty ''Logistical Packaging'' is done.

All in all, We would like to thank those who have tagged and posted their comments to us.

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