 Zero breakages goal
January 1st 2010
The Smartstak system addresses the
issue of pallet instability in transporting
glass bottles
The traditional method of transporting glass relies on flat
extruded plastic pads, wooden top frames, banding and
plastic bags, securing loads to a maximum of ten layers,
and not making significant moves towards zero breakages.
Loadhog recognised that its Lid product was not the
complete answer and was convinced a step-change product
could be developed to minimise breakages. Three of the UK's
largest glass bottle manufacturers worked with Loadhog to
develop the Smartstak system.
Industry statistics show 1% of all tall stacks collapse, or are
compromised during transit, and never reach their destination,
with the estimated cost to the industry exceeding ?2.5m.
Loadhog's technical challenges were to prevent bottles
'migrating' outwards during transit, and strapping losing
tension. The company worked with some of the industry's
major players, universities and tooling partners to bring the
Smartstak to market.
Smartstak required an investment of ?500,000 in tooling.
During the design process Loadhog tested assumptions and
minimised risk, utilising the Pira test laboratories to simulate
transportation movements.
The system comprises two elements. The Smartpad is a
plastic injection moulded layer pad with a unique waved edge.
It was developed to solve the stability issue, differing from the
profile of a conventional pad. Its edge not only provides the
glass block with stability but also encourages bottles to
'migrate' to the centre of the pad rather than to the edges,
eliminates bottle scuffing and acts as a barrier when a pallet is
subjected to impact forces. More than 500,000 pads are
currently on rental, moving in excess of eight million bottles
weekly.
The two-piece injection moulded Smartframe solves the
problem of strap tensioning, housing springs to provide
1,000kg stored energy, to compensate for the elastic properties
of plastic banding, and acting as a damper to ensure even
tension and load distribution throughout the life of the pack.
As fewer straps are required, the time needed to build a pallet
of glass is reduced by up to 20 per cent. Resulting from its
inherent strength, customers can confidently increase the
number of layers from ten to 11, reducing vehicle movements
by ten per cent. Savings in packaging are also generated by
reducing strapping and eliminating the need for shrouds which
have traditionally been disposed of in landfill.
A pool management system has been written and developed,
providing accurate data on pads' and frames' location, thus
minimising working capital in the supply chain and providing a
24-hour replenishment service.
Smartstak has not only set new standards in glass
transportation, but also made a significant environmental
contribution.Manufacture of the Smartpad utilises recycled
polypropylene in a factory which is 'best in class' for
environmental efficiency. Any product returned as damaged is
reground and utilised in the manufacture of new product.
This year, Smartstak has made significant progress. The
system is now being used by the most innovative glass bottle
manufacturers, major brewers and soft drink manufacturers.
Loadhog is confident that Smartstak will be adopted
progressively as the industry standard in the UK and Europe
and the company is already talking to other manufacturers to
license the technology in other parts of the world.
Smartstak demonstrates that innovation can be achieved in
mature industries. The product could help the glass bottling
industry reach its holy grail of
zero transportation breakages.
Australian breakthrough
Loadhog has opened up the Australian market by securing almost
£2m in sales to a leading global packaging manufacturer, after
investing almost £500,000 in bespoke moulding tools.
Under an initial £1m deal the new tools will produce 40 per cent
larger Smartpads and Smartframes for Amcor, one of Australia's
largest glass manufacturers.
After pilot testing Smartstak, Amcor has specified the system as the
standard method of transporting containers for its Australian and
New Zealand operations.
Smartstak operations manager, Dave Arthur, says: "These sales are
a major coup for Loadhog and well worth our investment. What is
especially pleasing is that this customer sees Smartstak as the
standard for transporting glass bottles, which is a major step
towards establishing the system as the industry standard, not just for
Amcor.We are currently talking to a number of other major bottle
manufacturers an
Australian breakthrough
Loadhog has opened up the Australian market by securing almost
£2m in sales to a leading global packaging manufacturer, after
investing almost £500,000 in bespoke moulding tools.
Under an initial £1m deal the new tools will produce 40 per cent
larger Smartpads and Smartframes for Amcor, one of Australia's
largest glass manufacturers.
After pilot testing Smartstak, Amcor has specified the system as the
standard method of transporting containers for its Australian and
New Zealand operations.
Smartstak operations manager, Dave Arthur, says: "These sales are
a major coup for Loadhog and well worth our investment. What is
especially pleasing is that this customer sees Smartstak as the
standard for transporting glass bottles, which is a major step
towards establishing the system as the industry standard, not just for
Amcor.We are currently talking to a number of other major bottle
manufacturers an More articles from Loadhog Ltd: | 
