A leading automotive OEM needed a robust packaging solution that allowed their customers to seamlessly repackage headlamps for return and protect the product from damages during shipment. Due to the complexity of repackaging with their current foam-in-place solution, the automotive manufacturer faced high damage rates, resulting in $9.8 million in annual losses. Leveraging proven expertise in automotive headlamp protection, Shorr collaborated with our trusted partner, Pregis, proposing the AirSpeed® ChamberPak as a solution. The result: $5 million in annual savings, $3.8 million of which came from reduced damages.
See why Shorr is the ideal partner for automotive packaging.
Shorr’s experience and collaboration with Pregis, a trusted partner, delivered impactful results.
Shorr and Pregis partnered to help the automotive manufacturer address two significant challenges:
- Identify a packaging solution for their customers to intuitively and securely repackage headlamps.
- Reduce product damage that was causing $800,000 in monthly losses.
Shorr and Pregis Conducted Comprehensive Testing to Ensure Efficiency.
We conducted two tests focusing on design performance and cost effectiveness. First, a cross-country shipment was performed across various headlamp sizes featuring the custom telescope design to assess product compatibility. The results showed all sizes remained undamaged in both outbound and return shipping. Second, a cost analysis was performed to compare their current foam-in-place solution. The result – $1.2 million annualized savings from packaging materials.
Implemented Custom Design for Maximum Protection.
The telescopic design successfully accommodated various headlamp sizes, confirming it could handle the company’s product diversity. ChamberPak features interconnected air chambers with patented one-way valves ensuring reliable protection by keeping other chambers inflated even if one is punctured. As a result, the manufacturer reduced damages by 50%, streamlined material management, and improved cost forecasting.
Shorr and Pregis partnered to develop a strategy that provided three key results for the customer.
Reduced Product Damages
Leveraging the Airspeed® ChamperPak enabled the manufacturer to reduce damage rates by 50%, saving $3.84 million in product damages and $1.2 million in packaging materials annually.
Optimized Operational Efficiency and Reduced Freight Costs
A single ChamberPak SKU replaced multiple foam configurations, streamlining material management and improving cost forecasting. By taking a customer centric consultative approach, the Pregis and Shorr teams positioned AirSpeed® ChamberPak as the lead solution allowing the automotive OEM to achieve operational efficiencies and reduced dimensional (DIM) weight for shipments. DIM weight classifications cut shipping costs across all headlamp sizes.
Improved Return Shipping Experience for End-Users
Leveraging a custom telescopic design, made it easier for customers to securely repack headlamps for returns. The versatility of the packaging size allowed the manufacturer to save materials and reduce waste. This user-friendly, sustainable solution highlights Shorr Packaging and Pregis’s strong commitment to innovation and measurable results in protective packaging.
- On-demand availability.
- Waste reduction.
- Labor cost reductions.
- Maximized output and product protection.
- Increased profitability.
- Customized to your needs.
If we could do any of this for your organization, wouldn’t that be worth a call? (888) 885-0055
