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 cases : In most of the cases, packaging of heavy engineering items is done in skid type cases and the base of such cases takes the entire load. Naturally the design of the base needs depends upon the gross weight, length and width of the box. In general, the height of skid is taken to be twice the width. The section can be designed by considering the bending during lifting either by forklift truck or by crane using slings. It is always better if the skid and end base boards are bolted instead of being nailed. The rubbing strips should be provided below the skids for ease in lifting. In order to avoid distortion of the case during lifting, diagonal battens are provided. For this reason the cases can also be reinforced by provided mild steel "L" angles at corners. Reinforcing straps add to the strength of the box and its section can be chosen based upon the tensile strength of the strap required as given below:
Tensile strength of the strap required = (gross weight x 10) / number of straps
By using this tensile strength, we can select different straps of the same cross section. However, it is desirable to select a strap which is wide enough, as this will avoid the biting into edges of the box.
Compatibility
This is determined by the nature of the product, surface characteristics and the properties of the packaging materials used. Properties of packaging material should be checked before its use. The physical contact should not contaminate the product and cause deterioration of the factory fresh finish of the product. Metal surfaces corrode, rubber product perishes, paper gets discoloured and disintegrated, fabric and leather rot or are mildewed. In this connection, it is always desirable not to use damp paper or damp wood wool or unseasoned timber, as they give to corrosion during the transit and storage.
Provisions for easy handling
The physical hazards encountered by the package during the transit can be reduced to a greater extent by using handling devices. Easy handling can be achieved by different ways as given below:
1) By providing the skids to the wooden case for ease in mechanical lifting
2) Odd shaped items give rise to uneven distribution of load in the pack and it is preferable to pack each item as two in one pack in such a manner so as to distribute weight uniformly. This can also be regarded as a provision of easy handling.
3) If it is not possible to pack two odd shaped items in one pack as mentioned in item (2) above, a proper aligning position or hook position should be marked on the package by ascertaining the position of its centre of gravity.
4) Instructions for opening should be provided or may be marked on the product at the time of packing. This will much reduce the chances of damage.
5) The dimensions of the pack should be such as to suit the shipping and lifting facilities.
6) In some cases, it is possible to provide handles to the package and make the package into "two to carry load".
Economic Considerations
The fulfillment of all the objectives of a satisfactory packaging system at the lowest possible cost is one of the most important functions of packaging scheme. It also involves continuous research of damage rates, protection and cost involved and establishment in relation to the type of the product, cost of the product and the quality of the product.
Procurement of materials
Once the packaging design is chosen, the necessity of procuring the raw material arises. The quantity of the material required per month or per specific period or as decided by the capacity of storing facilities, can be easily calculated. The main requirement is to set the standards for these materials and ascertain the proper supply from the vendors. The standard should be drawn for each material as well as the possible alternative materials. The material received should be stored in such a way that it does not get spoiled during storage. An example can be given of the corrugated board sheets. If they are stacked too high, the sheets at the lowest level get crushed and lose their cushioning property. Similarly the wood should not be stored in open space as it may deteriorate due to rain or may crack and wrap in the sun.
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