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*Ng Kim Leong (P04)
*Chew Meng Wei (P05)
*Seah Yan Lin (P05)
*Tan Mei Jia Bella (P05)
*Ye Shuying (P05)

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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.


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.

• 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

1. Versatility


2. High strength and low weight characteristics


3. Product containment and Protection features


4. Ready adaption to a wide range of product techniques


5. 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
  

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.

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:

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.

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