How To Re-use Corrugated Shippers 20 Times

On the sending side of the trial is Wiring Solutions Plus of Underdale, which makes wiring looms (also known as a wire harness, wiring harness, or cable assembly). On the receiving side is REDARC Electronics, which makes a range of electronic voltage converters, inverters, power supplies, battery chargers, brake controllers, and trailer braking products—in other words, products that require wiring looms made by WSP.

WSP ships thousands of corrugated cases of wiring looms to REDARC annually. In the past, the cases were taped closed. When REDARC received them, the tape was cut off with knives and all four top flaps were also cut off to facilitate ease of access to the components inside. The flaps and the cases were then disposed of. Not only is this procedure labor intensive and suboptimal from a sustainable packaging standpoint, it also poses the real risk of personnel lacerating themselves as they cut the tape and flaps.

In the ongoing trial, instead of taping the cases closed, WSP will close them with Box Latch^TM products. These are durable injection molded devices from Box Latch Products  that are anchored to case flaps to make it possible to securely close corrugated cases for transfer from WSP to REDARC. At REDARC, the top flaps are easily opened and the contents removed. When a case is empty, an operator opens the bottom flaps, collapses the case, and stacks the collapsed cases so that both cases and latches can be returned to WSP to be used all over again.This is how the reusable corrugated cases are closed and stacked for shipment from WSP to the customer participating in the trial.

Due to the uneven spread of weight in the single-wall cartons, WSP is trying two Box Latch™ Large on the bottom and one on the top to temporarily close the cases for shipping. Early testing at the WSP facilities by Phil Southam of KHP Business Solutions, the Australian Associate and Sales Representative for Box Latch™ Products, indicates two latches will hold the 11 kg weight in the current cases. “If WSP’s pilot program works as expected, it is likely WSP will move to double-wall corrugated cases to provide more strength, longevity, and security,” says Southam. More durable cases will cost a bit more but will prove to be cost-effective in the long run as well as reducing the need for two  Box Latches™ on the bottom.