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New casing strategy cultivates economy and ecology

Organic grower reinvents its shipper packing operations to minimize material usage and waste byproducts.

The new corrugated configurations incorporate tighter dimensions and eliminate interior dividers. Neither the inner cartons nor the outer shipping cases require foam peanuts for protective cushioning.
The new corrugated configurations incorporate tighter dimensions and eliminate interior dividers. Neither the inner cartons nor the outer shipping cases require foam peanuts for protective cushioning.

Gaia Herbs, Brevard, NC, is a certified organic grower and nationally branded manufacturer of herbal dietary supplements. The company cultivates 300 acres of medicinal herbs and operates a 45,000 square feet manufacturing and packaging facility. Gaia’s all-natural herbal products are marketed through health food stores and natural products retailers nation-wide.

Company VP of Marketing Ann Griffen Buchman notes, “In 2010, Gaia committed significant resources to re-branding and the development of the industry’s first herb traceability program.” And in 2013, the company received the first ever Award for Sustainable Excellence from the John Paul Selects organization. The judges cited use of solar energy for heating water at their manufacturing plant, wind power offset credits for 100% of Gaia’s power usage, and full compliance with the USDA National Organic Program among key reasons for the award.

In conjunction with these other environmental initiatives, Gaia Herbs also wanted to redesign its shipper packaging to save money, decrease product damage, and provide a positive environmental impact.

Upgrading by down-sizing
The previous shipper pack operation packed individual products into 11 different inner carton sizes and placed those inner cartons into one of 8 shipper case sizes, filling void space with biodegradable foam peanuts. Some of these cartons and shippers incorporated slotted dividers, and a full-time worker was needed to assemble the packaging.

Gaia convened an in-house team to analyze and improve its carton and casing systems and reduce its carbon footprint. The company also enlisted the assistance of packaging consultant Dr. Kenneth Marsh, Kenneth S. Marsh & Associates, Ltd., Consultants to the Food, Pharmaceutical and Packaging Industries.

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