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| Home > Articles > Packaging Of Industrial Products |
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Packaging Of Industrial Products |
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One disadvantage with this material is, it is not moisture-proof. This is taken care of by use of a polythene liner before putting them in the corrugated fibreboard box. This will also protect the surface finish of the cabinet against rubbing against the walls of the fibreboard box.
Package design may be discussed under two different heads:
· Unit Pack - Consumer pack
- Bulk Pack
In addition to the protection against hazards which the consumer packaging provides, it also projects the image of the radio, and certain instructions of handling. The design of the package matches the size and shape of the radio. The style of the corrugated fibreboard box will be generally RSC. The size of the corrugated fibreboard container will be a little over that of the radio, giving all round voids of about ½" to 1" depending upon the size and weight of the radio. The voids are filled up by fitments, e.g. cells or pads formed of single faced corrugated fibreboards. These interior packing pads provide adequate protection to the radios by bracing them at required points. Whenever polythene film cover is not used to cover the radios to prevent abrasion, the surface of the corrugated fibreboards to come into contact with the cabinet is lined with thin felt cloth. Sealing of the flaps is done by means of water activated gum-tapes usually of 2" width.
For shipping purposes, small open crates or fully enclosed cases or eleated plywood cases are made to accommodate 2, 4, 6, or 10 units packs depending on their sizes. Small sized transistors are packed even in lots of 10 per case or crate. Corrugated fibreboard pads are placed to isolate the units and provide extra cushioning. Dealers selling these products feel that they do not have many damages in these packages except in certain cases where the cabinets are slightly damaged.
A few manufacturers use solid fibreboard containers, also for consumer packs. Even here corrugated fibreboard pads are used as shock absorbing media. To render effective cushioning, rubberised coir or expanded polystyrene may also be used, but it is costly. Simulated tests are performed to evaluate the package performance against effects of mechanical shocks and climate. If the products are too expensive to be subjected to such tests, then the packaging design will have to be beyond the optimum level both in cost and efficiency.
For product identification, the corrugated fibreboard boxes are printed with necessary technical details and a brand image of the radio. The model code and serial number is also shown over the box. The case marking such as "keep this side up" - "Handle with care" - "Fragile" are also indicated by codes and lettering.
Severe losses will result when economy is not properly taken into consideration and a proper method adopted. The evaluation of this involves a number of considerations:
· Cost of the product
· Cost of packaging material
· Packaging operation, methods, cost
· Standardisation
· Cost of packaging as a percentage of product cost
· Transportation methods, freight consideration
It is of interest to note that in radios, the cabinets made of wood or plastic material themselves act as containers to the assembly within, thus contributing towards packaging.
Electrical goods
Electrical goods are of various kinds serving the needs of industry, agriculture, domestic, etc. The safety of the above products is dependent on the flow of electricity. Unless the current is controlled there is every danger to the life of the motor. Hence motor control systems grew as a subsequent requisite. This resulted in the manufacture of control gears. Our industry produces more than forty types of control gears with different features and with different protective devices. Each differs from the other in design and physical characteristics even though they may serve the same purpose. Some products in the family are: Motor Control Starters, Circuit Breakers, Reversing Switches, Loom Switches, Electronic Starters Distribution Panels, Switch Boards. The sizes vary from a small switch which can be held in the palm of a hand to a 25 panel high tension switch which needs a floor area of 20 m2 for installation. Some of our outdoor units are very tall structures, standing to a height of more than 6 m above the ground. The products vary in their size and shape as well as in their packaging needs which are based on the merits of each product including intricacy of its assembly. Generally the products comprise iron casting, sheet steel chambers, bakelite insulations, porcelain insulations, complicated operating mechanisms, oil tanks, angle iron frames, etc. Some of the products can be dissembled and some will have to go in an assembled condition. In the case of the latter the packaging becomes even more complicated. Wherever the projections of parts are inevitable, clear voids are to be provided as they have to be cushioned with suitable material. For heavy products the following points are to be observed:
1) To build an adequate case and to anchor the product inside to prevent movement.
2) Disassemble the possible parts and secure them with the main body.
3) To provide slinging hooks to handle the packages easily.
4) The package has to be simple but sturdy.
In packaging of products weight is unevenly distributed. Special care has to be taken for balancing the weight either by disassembling parts and fastening them at places where weight is to be added, or by packing two items together in such a manner as to even out the weight. The weight of our products varies from 500 grams to 1000 kgs each. So the packing pattern is of varied types because of diversified sizes, shapes and weights. Small products of regular shapes are packed first in unit sizes and further packed in shipping or bulk containers. Large sized products are packed individually in either crates or fully enclosed cases. The containers are made of wood of normal densities which are easily available from our forests - the selection of wood has been dealt with separately. Especially the moisture content of wood, defects, strength characteristics, styles of boxes, crates etc. Plywood cases are also made use of for bulk packaging of small products. The unit packages are normally made of corrugated fibreboard material with necessary fitments. To protect the units from climatic effects, bitumen coated waterproof paper, polythene films, polythene lined hessian and wax coated papers are used for export purposes. Silica gel is used as a moisture absorbent or desiccant. Water activated gum tapes, liquid gums are used. Heat sealers to seal polythene film are also used.
For cushioning, easily available dry paddy straw, dry wood wool, rubberised coir, corrugated fibreboard pads, etc, are used. Cushioning is provided to absorb shock energy developed when a package is dropped and also to isolate vibrations caused by the motion of transport. In providing fragile items, there is a considerable increase of cost, volume of the container and weight of packaging material. To attain a high degree of economy, the amount of cushioning material must be kept at the minimum, consistent with adequate protection. Formulae and tables have been developed to determine an optimum cushioning required, taking into consideration:
i) The intensity of shock and vibration that are encountered
ii) The capacity (fragility or G factor) of the product to withstand shock and vibration
iii) The mechanical properties of the cushioning materials.
Compression or tensional springs are also made use of either to cushion or suspend the product inside the container to keep it safe from mechanical hazards. Rubber mounts are also used at suitable places between these product and the container.
Blocking & bracing
Any product which is packaged should fit tight or be fixed and rendered immovable within the container, otherwise the product is sure to be damaged due to the impact of the product against the walls of the container. For this, it is necessary to resort to blocking and bracing. Regularly shaped products do not call for any complicated design of bracing but irregularly shaped ones may require an elaborate arrangement of bracing to secure the product. Wood blocking is widely used inside heavy packages because of high strength-weight ratio of wood, ease of cutting to any shapes and easy availability. It is important to exercise great care in the use of wood to take advantage of its structural properties and avoid its drawbacks. Sometimes wooden or metal frames or combinations of these are employed to facilitate immobilisation. Such requirements are often made by carefully designing the framework which could be prefabricated and set in place in the container. Marking is an important operation in the packaging line. A package is not complete unless the marking on the package helps to identify the packaged product and offer directions for opening the package in a safe and convenient way. For want of proper labelling, the package may have to be undone time and again for finding out its contents and in doing so various actions taken to preserve the item get nullified and repacking becomes not only costly but ineffective.
1) To provide specific handling, warehousing and opening direction.
2) To direct a package to the buyer.
The former includes positioning arrows, centre of gravity, slinging points, stacking position and precautionary directions to keep in proper environment. The latter which directs the package to destination includes such information as name, address, routing and order number, etc. It should be realised that precautions indicated over the package should be only for description and not as a substitute for a poor package. The machine head cover is made of plywood sheet and is attractively finished. It is very light in weight but bulky. This is also an accessory that is sent as per the choice of the buyer.
The packages will become very complicated if proper protection is to be afforded to it in assembled condition. For these two reasons the packs are separately packaged and the components are as follows:
1) Machine head: 1 case
2) Table: 1 case
3) Wheel, wheel guard, stand and pedal: 1 case
4) Machine head cover: 1 case
The machine head being a casting is prone to breakage. To simplify the interior packaging, the operating wheel is removed from the assembly. The container of a size suitable to package the machine head is made of ½" thick wood. Nailing cleats to the inside walls of the case on which the machine head rests forms a rib. The machine block is braced with wooden braces cut to semi-circular shape and fitted as cushion to hold the block. The machine head is covered with a polyphone film cover. The operating wheel wrapped in a wax-coated paper is securely nailed in one of the vacant spaces available in side. In advanced countries, this is packed in a corrugated fiberboard box, which can also be adopted in our country quite affectively. The table has good finish, which has to be protected against abrasion. One serious cause for damage of this table has been the chance of entry of water into the case. The top ply of the table that is stuck to the wood comes off. The weakness perhaps may be because of poor quality adhesive or the adhesive not being waterproof. Chances of the table getting broken are scanty, but in a few cases the board is found chipped. For economy and ease of packing, four tables are packaged together in a case for transportation between the producer and the dealer. The stands, the wheels, the guard and pedal are all packaged in one crate or case. Being casting, they are fragile. For cushioning the contents both wood-wool and paddy straw are used. Here also for despatches between the producer and the dealer, the bulk package contains four sets. The plywood cover which is to give protection to the machine head against dust is a little bulky but not heavy. Four of them are packed in a case, using paddy straw or wood-wool as cushioning material.
Refrigerator
A refrigerator may have different capacities, the most popular being 6 cu ft and 10 cu ft. The former weighs about 30 kg and the latter about 50 to 60 kg. A refrigerator mainly consists of a steel sheet cabinet with a door, a compressor, a condenser and a thermostat control. A refrigerator is noted for its air-tight construction, sealing out dust, air and moisture. This interior is divided into chassis and shelves each serving a definite required purpose. A compressor, which is assembled at the back near floor level is mounted on shock resisting springs. Another important feature of this is its finish. The exterior of the cabinet that is made of steel sheet is finished with lustrous enamel. The interior is made from high impact polystyrene amenable to easy cleaning, rustproof and ship resistant qualities. The door, which is also of enameled steel sheet, enables a perfect air-tight closing. Door handle, which is chrome plated, is of various designs and adds to the looks of the unit. The packaging of this product calls for a careful consideration of its service characteristics and finish. Even a small blemish or scratch on the unit would discourage its sale. Refrigerators, which are rugged in construction, could get damaged only with heavy drops and impacts. The compressor that is mounted on shock mounts and the thermostat control, the lamp fitting could all get dislocated with only heavy drops. As a packaging provision the refrigerators will be provided with bolting provision for shipping purposes.
The back of the refrigerator is fitted with a wiremesh; a polythene film is wrapped around the unit. A crate is constructed out of ½" thick wood. This will be a little over the size of the refrigerator. Felt pieces or pillow pack sheet are placed at the corners to brace the unit and thermocole or honey comb are also used over the top and bottom of the unit as cushion. Sufficient padding is given near the door handle to prevent any possible damage to it. The gross weight of the package should vary from 50 kg to 80 kg depending on the size of the unit. Markings for keeping the unit right side up and handling are stencilled over the package.
Heavy engineering goods
Heavy engineering goods consist of items such as industrial machinery, agricultural implements, chemical and textile fabricated items or machine parts. Essentially their density is high enough for them to be called as heavy goods. However, sometimes bulky items such as boilers, cylindrical shells are also grouped under the same heading. Many times these goods are strong enough to withstand impacts during the transportation but the accessories and the mounting which are going with them and are mounted directly on the outside or inside of the main body are likely to be damaged. There can be hazards such as corrosion due to climatic conditions. Here comes the function of packaging technologist to handle machines in all the directions - up, down and sideways to eliminate the movement is often required. This results in fixing of the machine inside the container and prevents its movement within the container.
Cast iron part : Care, should be taken to avoid undue weight and tension coming on such parts.
Internal padding : Padding should be inserted at all the contact points of products and construction timber.
Protruding members : As far as possible, the protruding members or overhandling members should be dismantled and packed separately within the main package. It is preferable to keep such components on the bottom of the case and fix them securely. If they must remain fixed on the machine, sufficient space should be left around them for suitable cushioning.
Giant machines ; For giant machines, many times it is desirable to dismantle such machines into sub-assemblies. For such packaging, care should be taken for proper identification of these sub-assembling easy for the consumer and to prevent mix up.
Precision parts : Special attention will have to be paid for packing of precision parts, gear boxes, shafts from the viewpoint of corrosion. This needs application of corrosion preventives e.g. protective oils and/or wrapping with laminates or films to protect such items.
Tools and accessories :Tools and accessories going along with the machine should never be sent separately. They can be packed within the main package to avoid the losses during transit or delay in receiving the parts.
Fixing of the machine : All machinery should be fixed firmly to the base with nuts and bolts, tensional straps or wooden blocks. Use of spring washer to avoid the loosening of bolts and nuts due to vibrations is also recommended.
Long & narrow parts : Parts such as axles, shafts, which are long and are likely to be damaged at ends or bent in the middle during the transportation should be uniformly and continuously supported. Solid wooden boards should be used for such purpose, instead of battened structure.
Brittle items : In the case of large and brittle items, the main danger is of fracture in the middle. In order to avoid this, they should be floated in cushioning material. Generally, giving cushioned supports at two points within its span does this.
No moisture should be allowed to enter the case : This can be achieved by using duly sealed waterproof lining materials such as bitumen sandwitched krafts, polyethylene film, polypaper laminates, jute-polyethylene laminates, etc.
Skid type ca |
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| Posted : 10/27/2005 |
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