"The $4 million we're saving in 1997 is in materials only" says 3M's Jerry Niles. "Added savings come in labor reduction. It used to take 10 people to package these reels and now it takes three. And on top of all that is increased efficiency in dockage. We used to need five dock doors to handle the bulky packaging materials we used before. Now all we need is a single dock door." The 1/2"-wide bulk videotape produced by 3M is wound into reels about 14" in dia. Before the new Reusable Pak was designed workers used to put eight of these reels into a one-way package consisting of 11 separate components including among other things two expanded polystyrene end caps paper dunnage and shrink wrap. "Each of these bundles generated about one cubic foot of waste" says Niles. Some customers he says tried to recycle the components but rarely could they recycle more than 22% of the total package. And even that amount required workers spending valuable time sorting and separating. The new Reusable Pak consists of two identical panels each having two living hinges and a core on which the rolls of tape are mounted. Though all three are made of high-density polyethylene the core is extruded and the panels are extrusion blown.