Challenge: Stephen Gould, a packaging broker, came to us seeking a solution for a client who ships machine coolers – heavy, radiator-like steel units. The existing packaging, which slotted together, frequently fell apart from the strain of holding five units at 65 pounds each. They challenged us with creating a new package with the same size and orientation, 40” x 8” x 5” that was more stable.

Solution: We had an idea, and it stuck. Really well. Glue the sides of a die-cut HSC (half-slotted container) box together and add corrugated partitions to create five compartments that would help alleviate shifting and stress on the sides of the package. The result was a solid-piece box that just needed partitions added at the manufacturing site.

Outcome: The new packaging dovetailed perfectly with the manufacturing process and equipment and created a 20% increase in production output. In addition, there have been no incidents of package failure.