The challenge for Quality Carton, an East Coast home improvement materials company, was to reduce shipping and handling damage on long, heavy panels.
UChannel has played an important role in helping reduce their damage rates by two-thirds.
The panels, which are three-quarters of an inch thick and made of melamine, used to be cushioned inside Quality Carton's corrugated boxes by an expanding sealed foam system that molds itself to the contours of the product and box. But even with foam protection, breakage rates were running as high as three percent.
"A typical package is very heavy and dense. Also, they are sometimes handled roughly during shipping," said Liam Quinn, Vice President of Sales for Quality Carton, headquartered in Mahwah, New Jersey.
"When one of these packages is dropped on the ground, the impact of 70 pounds on that three-inch edge is significant. We needed additional materials that would absorb that impact, not just on the first drop but on any subsequent drops as well," Quinn said. "Also, there was very little lateral strength on one of those six-foot panels, so they had the potential of snapping during transit."
Interior protective packaging is now a solution that involves UChannel and honeycomb. Inside the Quality Carton box, UChannel is used to protect the long edges of the panels and bolster lateral strength. Honeycomb provides additional interior cushioning for the face panels and panel edges, which now can withstand being dropped multiple times.
"In addition to protecting the edges from impact damage, UChannel provides supplemental lateral strength to a package that otherwise would have very little lateral strength," Quinn said. "Damage rates are now below one percent."
UChannel helped decrease Quality Carton's damage rate from 3% to under 1%.