When one of India's leading electronics manufacturers approached us with a persistent transit damage problem, we saw an opportunity to demonstrate how engineered packaging can transform outcomes.
The Challenge
The client was experiencing a 12% damage rate on their LED panel shipments to Southeast Asian markets. Their existing packaging, generic single-wall boxes with foam inserts, wasn't providing adequate protection during multi-modal transit (truck, rail, and sea freight).
Our Approach
We conducted a full packaging audit, including drop tests, compression tests, and vibration analysis. Our engineering team designed a custom double-wall corrugated solution with die-cut internal fitments that cradled each panel, eliminating the need for loose void fill.
The Results
Within the first quarter of deployment:
- Damage rate dropped from 12% to 4.8%, a 60% reduction
- Material costs reduced by 18% by eliminating foam inserts
- Packing time reduced by 25% with snap-fit internal fitments
- 100% recyclable packaging replaced mixed-material solution
Key Takeaway
Engineered corrugated packaging, designed around your specific product and logistics chain, consistently outperforms generic solutions, often at lower cost.