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Textbook seller learns a lot about cushioning

Follett Educational Services cuts both costs and customer complaints by switching from foam-in-place to an air cushion void-fill system.

Packers can easily choose how many bags to place in boxes to protect the books. This system makes it easier for packers to use
Packers can easily choose how many bags to place in boxes to protect the books. This system makes it easier for packers to use

Although text books seem to be pretty strong, they still need protection in shipping. That's why Chicago-based Follett Educational Services goes to such lengths to protect its grade- and high-school textbooks from damage during distribution across the country.

Follett, the nation's largest provider of textbooks and instructional materials, has changed its protective packaging strategy a number of times. The company began by using wadded-up paper. Later it changed to foam-in-place cushioning. While the foam-in-place was much more efficient than the paper packaging, it created a new set of problems for Follett.

"The foam-in-place caused huge housekeeping problems for us," says Dan Newton, Follett's vice president of distribution and facility. The foam leaked onto books, packers and conveyor lines. Storage was no picnic, either.

"We had to store and dispose of 50-pound barrels of chemicals," says Newton. "There was considerable waste because the foam bags didn't always fit the material in the carton. But more important, our customers complained about foam on the books they received."

After two years of using the foam system and receiving numerous complaints, Newton decided it was time for a change. At the beginning of 1998, Packaging Solutions (Elk Grove Village, IL) introduced Newton to FP Intl.'s (Redwood City, CA) Cell-O Flo-Pak void-fill machine. Follett liked the system and decided to make the change. Extruded of high-density polyethylene, the 1.6-mil Cell-O bag material comes to Follett as rollstock in the form of a tube.

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