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Cushioning change gives Earthtones damage control

Earthtones, Inc., Tucson, AZ, a manufacturer of decorative ceramic tiles, had for years lived with a 15% damage rate for its tiles packed in 30-lb corrugated boxes.

Pw 14632 Earthtones1

The 6x6’’ tiles sell for about $15 apiece through a variety of channels from home improvement to gift to hardware stores. The tiles are packed on end, 26 to a corrugated case that is placed inside an outer corrugated shipper. Cushioning is used between the two cases.

“We used a thick, expensive air cushioning product to protect our tiles,” says general manager Brian Young. When the manufacturer discontinued producing the cushioning, Earthtones scrambled to find a replacement. Solutions like expanded polystyrene pellets, corrugated corners, and even newsprint couldn’t keep damage under 25% to 30%.

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