A major producer of natural cosmetic products needed to introduce a reusable container for semi bulk shipments for a variety of products that could also be used as a storage unit and pick-bin. The original half slotted container and stitched cap had proved the correct size, but the caps were seldom returned and tape damage seriously reduced the lifecycle of the containers
The replacement design from DS Smith Tri-Wall utilizes a novel 'jig-saw' outer base flap system to simplify make-up, breakdown for flat packed returns and to avoid the need for taping. The inner flaps were increased to meet giving a flat surface for filling irrespective of the product mix. A saloon style door was introduced in a main panel with a three-quarter length vertical slit, parallel vertical creasing and a cross panel slit at the bottom of the doors. This allowed the two panels to be easily turned back to fold flat against the container where they are held in place by the easy to use locking tabs in both the main body of the case and the doors. The vertical slit extended past the door panels so that an 'H' section plastics extrusion slid in place and maintained the integrity of the pack both in storage and transit, with the upper end retained by the cap.
With weights of product approaching 600kg the main container material was changed to a double 'A' flute material of MOD quality for increased stacking strength. For the pack to be truly reusable the cap was redesigned to be self locking and as it also had taken on a more structural role the material was changed to a BA flute combination that gives both strength and durability.
Since the introduction of the design the cosmetic manufacturer has reported an easier and quicker pack erection with reduced fill times. Similar reports are being received from distribution centres and end users alike when unloading. The return rate of flat packed containers has improved and the environmental reputation of the manufacturer is said to have been enhanced.
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