Hi Jim. You’ve worked within the industry for more than 30 years. In your experience, how important a consideration is minimising product damage for supply chain managers?
The associated costs of product damage - either when moving items through the warehouse or on the back of a vehicle - have always been a problem for businesses. However, with rising overheads and tighter margins, supply chain managers are under greater pressure to minimise product damage and find solutions that not only protect goods but also contribute to more efficient and sustainable logistics. Any cost savings that can be made are vital.
Now more than ever, businesses must establish how much product damage costs and what can be done to mitigate it. We’ve definitely seen a rise in the number of customers asking about specialist products that provide better protection – especially our plastic returnable transport packaging (RTP).
Interesting. For those that might not be familiar with the term, what is returnable transport packaging (RTP) and why use it?
RTP is extensively used across various industries, including manufacturing, automotive, pharmaceutical, retail and more. This type of packaging comes in many forms, including pallets, pallet boxes, containers, crates, and trays. While RTP is typically made from plastic, wood or metal, we focus on recycled plastics, as they are more robust and recyclable at the end of their lifespan, which contributes to the circular economy. Unlike single-use packaging, RTP is designed for repeated use over many years. Therefore, despite a higher initial investment, the potential for multiple uses over a long period of time (unlike single-trip packaging) can offer a lower cost per trip overall.
Could you tell us about the day-to-day benefits of using RTP?
Of course. RTP offers a wide range of benefits that make it an excellent choice for modern supply chains. Unlike single-trip packaging (such as cardboard boxes), which often requires shrink-wrapping, plastic boxes with integrated lids/bases eliminate the need for tape, saving time and resources. These boxes are quick and easy to use, making dispatching orders more efficient, and their enhanced strength provides increased protection during transit.
With uniform shapes and sizes, RTP ensures consistency in handling and stacking, which, naturally, will lead to less damage. Plus, foldable options save valuable space when not in use or during return journeys.
From your experience or conversations, how are products most commonly damaged in the supply chain?
The most common way products become physically damaged in the supply chain is when they shift during transit, or when they are being moved by forklifts. Therefore, the stability, construction, material, and strength of packaging are crucial.
If you’re regularly shipping large quantities of products, there’s a lot to think about: How robust are the boxes, pallets or containers that your goods are shipped in? Can they be stacked safely and securely? Is your packaging/equipment appropriate for heavier items?
Ideally, when it comes to pallets, products are stacked and positioned tightly with zero space in between. Individual pallets are then often wrapped with shrink wrap and anchored to prevent movement. However, as I said earlier, plastic pallet boxes offer a brilliant alternative.
If gaps occur, you’re leaving the integrity of each pallet and load to chance. Sudden braking in transit, rough terrain, or jerky forklift operation can cause packed products to move and become more susceptible to damage.
That makes sense. So, what are the benefits of plastic pallets over wooden pallets when it comes to product protection?
Wooden pallets can directly contribute to product damage. Essentially, unless you’re using brand new wooden pallets, you’ll never know how strong they truly are, or when they are likely to fail. Wooden pallets will weaken over time, whilst some will suffer from inconsistent gaps in deck board spaces. You’ll also be aware that wooden pallets can break or splinter easily, whilst protruding nails also pose a risk to products. In addition, wooden pallets can often be a weak link in an automated warehouse. Minimal deflection of a pallet is important to allow safe long-term storage and efficient retrieval of the goods without any compromise of the stored products or materials.
Plastic pallets address many of these shortcomings. Significantly, unlike wooden pallets, which can have gaps between deck boards, plastic pallets have a more consistent deck coverage, which means products and external packaging can’t slip into gaps.
Plastic pallets and containers are far more robust. For example, a high-quality plastic pallet will absorb any impact rather than potentially splintering or cracking. Plastic pallets are moulded individually as one piece with easy to clean surfaces; they don’t use nails and there are no individual boards to pull loose.
Using a robust plastic pallet, chosen specifically to match your usage, will reduce damage, saving both time and money.
Finally, what buying trends have you seen over the last 12 months?
As you’d expect, we have seen a significant growth in the number of enquiries from businesses looking to switch from wooden pallets to plastic ones. Thankfully, we have the largest range in the UK, so we have a number of different options available for any application.
To support this trend, we have also seen a 22% rise in sales of foldable sleeve-packs during 2024 too. The CabCube 1210 9F 2.0 (measuring 1210mm x 1010mm x 990mm) has a unique, injection-moulded closed base and lid for supreme strength. This innovative product has a 875-litre capacity, and, when collapsed, its height is reduced by 75%, which substantially cuts return costs .
In addition, sales of folding large containers - such as the GoFLC 980 (a 1200 x 1000 x 980mm box that holds 847 litres, but has a folded height of just 317mm when not in use) - have jumped by more than 30% year-on-year. It’s a super heavy duty product that incorporates a door, so it can be loaded and unloaded easily – helping to further minimise potential damages.
For more information, please visit www.goplasticpallets.com