Country: Japan

Category: Transit

The conventional packaging method using wooden pallets has been replaced with a newly developed cardboard-based solution. The packaged items are slurry pumps, which come in ten different types, each varying in shape and weight. Some pumps weigh up to 200 kg. Due to this diversity, it was difficult to standardize packaging materials using typical cardboard solutions.
To overcome this challenge, we developed a specialized cardboard pallet that allows the legs of the pump to be bolted directly to the pallet. This design provides sufficient strength to withstand bolted fastening and features a flexible structure that enables the bolt positions to be freely adjusted. As a result, pumps of various shapes and sizes can be securely fixed without the need for different packaging materials.
The new packaging system has significantly improved operational efficiency. Assembly and packing time have been reduced by 70%, while unpacking time has been reduced by 90%. Additionally, the transition to cardboard has eliminated industrial wood waste and reduced CO₂ emissions by 61%, successfully addressing all the issues identified prior to the redesign.
To verify the impact resistance and ensure that both the packaging and the product remain undamaged during transportation, we conducted a cantilever edge drop test. The packaging passed the test, confirming that the pump and packaging materials remain intact even when subjected to impact. This result is largely attributed to our proprietary high-strength reinforced cardboard, which is highly resistant to tearing even under stress.
Previously, the assembly of wooden pallets was complex and involved hazardous tasks such as nail-driving, which limited the number of personnel qualified to perform the work. With the adoption of cardboard packaging, the assembly process has become much simpler and safer. The elimination of nail-driving has made it possible for anyone to carry out the packaging work, regardless of skill level.
Furthermore, the top surface of the cardboard pallet includes slots for PP bands, allowing for flexible fixation of various accessory items. These items may differ in size, shape, and quantity, but can still be securely fastened using the integrated banding system.
This packaging innovation not only improves safety and efficiency but also contributes to environmental sustainability and operational flexibility. It represents a valuable solution for the logistics of heavy industrial equipment, offering a standardized, eco-friendly, and user-friendly alternative to traditional wooden pallet systems.