David S Smith Tri-Wall has helped an automotive parts producer to reduce storage space and packaging waste with a bespoke version of its Tri-Wall dunnage system.

The pack, which is used to ship metal cylinder sleeves to a US customer, retains the footprint and pallet of the original system but now features a corrugated dunnage system. Holes matching the differing profiles of the cylinders are cut into heavy duty corrugated board that is glued to layered pads to form retaining fittings. By die-cutting the elements, product can be packed closer together, giving an increase from 25-32 cylinders per layer.

With the new pack, corrugated pack items are reduced from 38 to five and packing time is down by 9%.