When manufacturers look for supply chain savings, transport packaging is rarely the first place they look. Yet for organisations moving components across international supply chains, smarter packaging can deliver significant improvements in warehouse efficiency, transport costs, sustainability and product protection.
That is exactly what happened when global aerospace manufacturer Safran approached Antalis Packaging to repair a fleet of ageing transit cases used to transport aircraft landing gear. Rather than repairing worn steel containers, Antalis challenged the brief, designing an intelligent transport solution that is now reducing transport costs by around £12,000 every month, while improving handling, safety and operational efficiency throughout the logistics chain.
The project illustrates a growing trend across manufacturing and logistics. Packaging is no longer viewed simply as something that protects products during transit. It is increasingly an integral part of warehouse operations, inventory management and supply chain optimisation.
Safran's existing transport cases had reached the end of their operational life. Manufactured from steel, they had become heavy, corroded and difficult to manoeuvre. While the original request centred on repairing the damaged units, Antalis Packaging recognised there was an opportunity to rethink the entire process.
Instead of designing another transport case, the packaging specialists began by analysing the products themselves, how they were stored, handled and presented to engineers. This reverse-engineering approach placed the aircraft components at the centre of the design process, allowing the packaging to become an operational tool rather than a protective container.
The result was a new transport system consisting of two bespoke case designs. One incorporates lockable drawers containing colour-coded foam inserts for smaller components, while the second accommodates individual landing gear parts weighing up to 150kg. Constructed from lightweight plywood with an aluminium frame, the new cases are substantially lighter than their predecessors while offering greater durability.
For logistics, however, the greatest benefits come from the operational improvements built into the design. The cases are stackable, reducing storage space and making better use of warehouse capacity. Integrated forklift pockets allow faster loading and unloading, while heavy-duty lockable wheels improve manoeuvrability during movement around production and storage facilities.
Efficiency extends inside the cases as well. Each drawer is numbered to reflect the order in which components are required during aircraft assembly, while colour-coded foam inserts aid in identifying parts.
The commercial results have been equally impressive.
Reducing the weight of the cases by approximately 30% has lowered transport costs. Combined with the more compact, stackable design, the new solution is now delivering transport savings of around £12,000 per month. The repairable construction also supports sustainability objectives by extending service life and reducing material waste by replacing individual panels rather than entire units.
The development followed a structured collaborative process. Antalis Packaging visited Safran to observe the existing operation before developing prototype designs that were refined through consultation with the customer. Following testing, 48 bespoke transport cases were produced and are now transporting landing gear components for both Boeing and Airbus programmes.
Jordanna Price, New Business Development Manager, Antalis Packaging, “The initial requirement was to repair existing cases, but we knew we could provide a better solution. Durable, repairable, sustainable and easier to use, the new flight cases have helped improve operational efficiency, reduce costs and cut environmental impact."
As supply chains continue to come under pressure to improve productivity while reducing costs and emissions, projects such as this demonstrate that packaging has become a solution capable of improving warehouse performance, simplifying logistics operations and delivering commercial returns.
Find out more by visiting www.antalis.co.uk/packaging or email the team at pkteam@antalis.co.uk