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Perfect Protective Packaging
FOAMplus® - Foam cushioning for perfect product protection
Close to the customer around the world National markets have different requirements and needs — despite globalization. In order to meet these needs, and to be as close to the customer as possible, the Storopack Group has a decentralized structure. Offices in each country act independently, quickly and flexibly.
Copyright© 2014 Storopack. All Rights reserved. 0914
NORTH AMERICA
[email protected] www.storopack.us
Cincinnati Head Office4758 Devitt DriveCincinnati, Ohio 45246Phone +1 513 874 0314Fax +1 513 874 2955
Cincinnati 4663 Dues DriveCincinnati, Ohio 45246Phone +1 513 860 1804Fax +1 513 860 4082
Atlanta 6140A Duquesne DriveAtlanta, Georgia 30336Phone +1 404 344 6451Fax +1 404 344 4734
Boston 125 Flanders RoadWestboro, Massachusetts 01581Phone +1 508 366 1249Fax +1 508 366 9539
Chicago 320 Craig PlaceHillside, Illinois 60162Phone +1 708 547 8030Fax +1 708 547 8096
Cleveland 3135 Berea RoadCleveland, Ohio 44111Phone +1 216 941 7225Fax +1 216 251 4744
Dallas 5050 Duncanville RoadDallas, Texas 75236Phone +1 972 296 9535Fax +1 972 296 9843
Los Angeles 12007 S.Woodruff AvenueDowney, California 90241Phone +1 562 803 5582Fax +1 562 803 4462
Memphis 4290 Delp StreetMemphis, Tennessee 38118Phone +1 901 367 8053Fax +1 901 367 8055
Miami 11825 N.W.100th Road,Suite 4Medley, Florida 33178Phone +1 305 805 9696Fax +1 305 805 9697
Minneapolis 13100 12th Avenue, NorthPlymouth, MN 55441Phone +1 763 542 8351Fax +1 763 542 3147
Newark 22 World’s Fair Drive, Unit DSomerset, New Jersey 08873Phone +1 732 560 1489Fax +1 732 560 1494
Phoenix 77 North 45th AvenuePhoenix, Arizona 85043Phone +1 602 484 0831Fax +1 602 278 1011
San Jose 2210 Junction AvenueSan Jose, California 95131Phone +1 408 435 1537Fax +1 408 922 0316
Seattle 20418 87th Avenue SouthKent, Washington 98031Phone +1 253 872 6844Fax +1 253 872 5722
Tampa 4724 Transport DriveTampa, Florida 33605Phone +1 813 247 4226Fax +1 813 247 3677
Winston-Salem 2598 G Empire DriveWinston-Salem, North Carolina 27103Phone +1 336 765 7767Fax +1 336 760 4426
Toronto 10 Woodslea Road, Unit 2Brampton, ONT L6T 5P2Phone +1 905 792 9567Fax +1 905 792 8737
SOUTH AMERICA
BRAZILwww.storopack.com.br
São Paulo Rua Tianguá, 13504363-100 São PauloPhone +55 11-5677-4699Fax +55 11-5677-4699
ASIA
HONG [email protected]
New Territories Unit A, 6th FloorWah Wing Ind. Bldg.14-20 Wing Yip StreetKwai Chung, N.T.Hong KongPhone +852 3421 2392Fax +852 3421 2720
EUROPE
Metzingen Head OfficeUntere Rietstraße 30D-72555 MetzingenPhone +49 (0)7123 164-0Fax +49 (0)7123 164-119
Service Center Max-Holder-Str. 19D-72555 MetzingenPhone +49 (0)7123 164-0Fax +49 (0)7123 164-246
Dietzenbach Waldstraße 32D-63128 DietzenbachPhone +49 (0)6074 48 70-150Fax +49 (0)6074 48 70-166
Hamburg Asbrookdamm 40D-22115 HamburgPhone +49 (0)40 7 15 99-0Fax +49 (0)40 7 15 99-44
Mülheim (Ruhr) Gewerbeallee 11D-45478 MülheimPhone +49 (0)208 589 89-0Fax +49 (0)208 591 812
Wildau Gewerbepark 31D-15745 WildauPhone +49 (0)3375 57 8-6Fax +49 (0)3375 57 8-700
Nully 10, Rue de L‘OrgissetF-52110 NullyPhone +33 (0)3 25 55 41 52Fax +33 (0)3 25 55 46 04
Sheffield 8 Julian RoadRoman Ridge Industrial EstateGB-Sheffield S9 1FZPhone +44 (0)114 249 2004Fax +44 (0)114 249 2006
[email protected](Belgium & Luxembourg)www.storopack.nl (Netherlands)
Machelen Head OfficeNieuwbrugstraat 79B-1830 MachelenPhone +32 (0) 2 756 80 90Fax +32 (0) 2 756 80 70
Harelbeke Kortrijksesteenweg 321/1B-8530 HarelbekePhone +32 (0) 56 35 72 55Fax +32 (0) 56 35 07 68
Wuustwezel Kerkplaats 7B-2990 WuustwezelPhone +32 (0) 3 669 99 80Fax +32 (0) 3 669 91 94
Sant Boi de Llobregat Andorra, 4E-08830 Sant Boi de Llobregat(Barcelona)Phone +34 93 6 525 210Fax +34 93 6 309 550
Stetten Im Stetterfeld 1CH-5608 StettenPhone +41 (0) 56 677 87 00Fax +41 (0) 56 677 87 01
Perfect Protective Packaging
Storopack-Your International Partner for Protective Packaging 3
FOAMplus®-Foam padding for perfect product protection 5
Always Customized:FOAMplus® protective packaging 7
FOAMplus® machine types 11
FOAMplus® - Types of Foam, Containers, Films 13
FOAMplus® Reference Projects 15
Sustainability and Environmental Protection 19
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Storopack – Your International Partner for Protective Packaging
You will find a general overview of customized and versatile protective packaging solutions at www.storopack.us.
The Storopack Packaging business segment offersflexible protective packaging solutions. Completeconsulting optimizes the protective packaging, theprotective packaging process, and its integration into acompany's internal logistics for maximum productivityand sustainability. An added dimension considers therecipient of the package. They should experience theprotective packaging solution in a positive way duringunpacking. The combined result is Storopack’s PerfectProtective Packaging.
At Storopack we continuously improve the productivityof our customer’s protective packaging process
Storopack offers four types of flexible protective packaging solutions: AIRplus® air cushions, PAPERplus® paper cushioning mattresses, FOAMplus® polyurethane foam cushions, and loose fill including PELASPAN® and PELASPAN® BIO.
Our “Working Comfort” consulting approach ensures ergonomics, efficiency and effectiveness in the packaging area. Upon request, specialized application engineers can provide customized solutions ranging from equipment for individual packaging station's to design and implementation of entire packaging lines. Storopack integrates manual,as well as partial and fully automatic packaging systems into intralogistics.
The globally active corporate group is represented atlocations in North and South America, Europe and Asia.Storopack's flexible protective packaging can bepurchased from dealers in over 40 countries.
Working Comfortby
Perfect Protective Packaging
FOAMplus® - Foam padding for perfect product protection
FOAMplus® foam cushioning provides customized, effective and lightweight protective packaging. Produced as you need it, this packaging foam conforms to fit any shape. The physical characteristics of this expanding synthetic provide package contents with durable and effective protection against stresses and strains during transport. The foam cushioning is lightweight yet excep-tionally impact-resistant and long-lasting. The recipient can see and feel the premium protection provided by this packaging material.
FOAMplus® foam cushioning is available with two types of equipment: a foam-in-bag system and a foam direct-injection system.
The Advantages of FOAMplus®:
▪ Superior foam quality: the same cushioning effect as alternative foam cushion systems that use 45% more materials▪ Efficiency: extremely impact-resistant, exceptional padding characteristics▪ Universal foam: maximizing strength and minimizing chemical usage for both heavy and lighter packaging▪ Robust: also suitable for sharp-edged items and very heavy objects▪ Customizable: conforms to the shape of an object as it hardens▪ All-purpose: protects items of virtually all sizes, shapes and weights▪ Versatile: can be used on selective areas or as an all-round covering▪ Saves space: on-demand system provides for minimum warehousing
5Picture 1 FOAMplus® foam cushioningPicture 2 FOAMplus® foam cushioning
The general protective functions: A pathfinder
This overview describes the general functions of protectivepackaging. In the following pages, the pathfinder identifies each function provided by the specific protective packaging material. Cushioning: Absorbs impacts and protects breakables.Void Filling: Fills empty spaces and prevents products from banging into each other.Block & Bracing: Stabilizes heavy objects or individual articles in their position.Wrapping: Protects completely against contact damage such as impact and scratches.
Perfect Protective Packaging
Always customized: FOAMplus® protective packaging
There are more uses for FOAMplus® than we can show here. In fact, its uses are virtually unlimited. This guide demon-strates a few of the more common ways that FOAMplus® foam cushioning can be used as protective packaging. Storopack can recommend how to make the most efficient use of our cushioning on a case-by-case basis. We furnish the customer with a packaging sample that can be easily put into operation.
Padding with foam cushioning The protective packaging completely fills the space in the box. The contents are sandwiched between two foam cushions and completely enclosed by packing foam.
▪ Very simple to pack▪ Sample use: highly sensitive items
Filling in spaces Foam cushioning is placed alongside and on top of products to fill in any remaining empty space inside a box.
▪ Fills gaps around sensitive items▪ Sample use: heavy, prepackaged products
Block and brace with foam cushioning When the foam cushioning only fills a portion of the box, additional padding can be added in specific locations, like the corners and edges of an item and across multiple objects.
▪ Economical use of materials▪ Sample use: securing and cushioning individual items
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FOAMplus® foam cushioning:In-carton applications FOAMplus® packaging foam configures itself to the shape of the product, securing it firmly in place. Even the slightest bit of movement within the container is practically eliminated. The polyurethane expands automatically, ensuring that gaps are correctly and completely filled in at the appropriate places. Our foam cushioning provides exceptional padding performance.
The protective functions of FOAMplus®
▪ Cushion▪ Void-Fill▪ Block and Brace
Picture 1 Packaging protection using FOAMplus® foam cushioningPicture 2 Packaging protection using FOAMplus® foam cushioningPicture 3 Packaging protection using FOAMplus® foam cushioning
Perfect Protective Packaging
Additional option: Pre-molding FOAMplus®
Storopack offers consultation, design, mold/cushion pro-duction, and equipment for end user in house pre-fabricated FOAMplus®. In the pre-fabricated process, packaging foam is applied into a positive mold of the shape required. Storopack can provide finished FOAMplus® cushions or a mold to be used to produce cushions on site at the customers location. Pre-molding can be done using various types of platforms from a table-top device made of wood to a dual-station on a wheeled stand.
▪ Create ready-made foam padding in desired quantities▪ Sample use: as a substitute for the original packaging▪ Sample use: when molded EPS/EPP/PE die cuts packaging would be uneconomical for small lots▪ Order Pre-Fabricated Cushions from one of Storopack’s North American Operations
Additional option:Direct injection using FOAMplus®
Foam cushioning can be directly injected for objects which are especially large in size, heavy or oddly shaped.
▪ The genuine solution to especially challenging packaging tasks▪ Sample use: Formula 1 racing engines
Additional option: FOAMplus® Tubes
FOAMplus® Tubes, linked foam padding, offer the best option where a chain of cushions is the most suitable form of packaging – and when you need the premium protec-tion provided by polyurethane. Products can be completely wrapped inside chains of foam cushioning.FOAMplus® Tubes are made using the foam-in-a-bag system, FOAMplus® Bagpacker (see page 11). You can select both the length of the chain as well as size and amount of filling material needed. Foam padding chains are best suited to pre-production.
▪ For smart packaging variations▪ Sample Use: lining boxes with two chains of padding▪ Sample Use: un-filled film segments – foam padding only where it’s really needed
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FOAMplus® foam cushioning:Sample uses Protective packaging using FOAMplus® meets even the highest standards. That’s what makes it perfect for
▪ returned goods (reverse logistics)▪ replacement parts logistics▪ as an alternative to original packaging▪ an alternative to molded packaging made of EPS (Styrofoam), EPP and PE die cuts▪ shipments containing both heavy and fragile items▪ shipments of artworks▪ medical devices▪ lighting
Picture 1 FOAMplus® Tube foam cushioningPicture 2 Pre-fabricated FOAMplus® foam cushioning
Perfect Protective Packaging
FOAMplus® machine typesA reliable partner for convenient on-demand production of foam cushioning.
▪ film rolls in three different widths▪ output: sequential production (timed) or manual operation▪ size and fill-level can be set individually
SpecificationsSize: 59“ x 79“ x 29.5“ Weight: 770 lbs. Power : 220 V, 30 amps Speed: 23 bags per minute
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Performance characteristics:Computer controlled and low maintenance
▪ easy to use▪ software-guided, constant process control▪ packaging produced on-demand at the push of a button▪ administrator level: over 500 programming positions▪ low maintenance due to advanced technology▪ produces protective packaging of consistent quality▪ self-cleaning mixing chamber
Picture 1 FOAMplus® BagpackerPicture 2 FOAMplus® HandpackerPicture 3 FOAMplus® Bagpacker Display
FOAMplus® Bagpacker
FOAMplus® HandpackerThis device is both fast and capable of producing foam of consistently high quality.
▪ self-cleaning mixing chamber▪ integrated diagnostics software▪ film directly from the roll – can include cutting system
SpecificationsSize: 29“ x 56“ x 16“ Weight: 375 lbs. Power : 220 V, 30 amps
Perfect Protective Packaging
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FOAMplus® foam types Production of foam cushioning takes place in the same manner no matter which type of machine is used: The unit mixes together two liquid components, producing (H)CFC polyurethane, which expands for a few seconds before setting. The packaging foam is available in a variety of densities, differing by unit weight, firmness and padding effect.
Available in grades ranging from 29 lbs. per cubic foot to 1.23 lbs. per cubic foot in density, FOAMplus® provides the answer for practically every need. Storopack can provide guidance about which degree of hardness is best suited for specific types of goods and shipping routes.
Picture 1 FOAMplus® foam
FOAMplus® - Types of Foam, Containers, Films
Incomparable: FOAMplus® Universal Foam This type of foam formulation reduces packaging costs and saves resources. FOAMplus® Universal Foam formulations have exceptional compression strength while maximizing yield (chemical usage). Therefore, offering equal or improved product protection while utilizing less raw materials.
▪ extra strong▪ extra light: lower unit weight▪ economical: lowers materials usage and shipping expenses
FOAMplus® Containers Storopack supplies containers in different sizes: metal drums with 55 gallon and 275 gallon capacity containers. One container is deployed for each foam-producing component. Storopack provides for the timely exchange of drums and containers.Please contact your local Storopack facility for available sizes.
FOAMplus® film types
Storopack produces film at its own facilities. This ensures a consistently high level of product quality and supply reliability.
▪ FOAMplus® Standard Film: co-extruded, durable film in three roll widths
▪ FOAMplus® ESD Film: anti-static film, meets your need for statically conductive materials
Perfect Protective Packaging
Integration for a direct marketing company
Products:Workshop supplies, assembly and fastenersEquipment:Seven FOAMplus® BagpackersProduction rate per packing station:26 seconds per shipment (average)Total production rate:7800 shipments / day (average)
Our challenge: This major retailer has a highly automated central warehouse. The protective packaging system must enable individual packers to process rapidly. The contents of the shipments present a wide variety in terms of protec-tion needed during transport. In some cases, for instance, fragile items are packed together with heavy objects.
Our Solution: FOAMplus® foam pads secure all articles in place inside the package while also providing heavy objects with sufficient cushioning. In dealing with ship-ments of individual parcels, there is no way to control what might be placed on top of a shipment during trans-port. FOAMplus® solves this problem by considerably improving the crush strength of cardboard packaging. FOAMplus® Bagpackers produce up to 23 cushions per minute. The supply of foam component materials are delivered to all machines from containers located one floor below which are easily accessible.
What the client has to say: "We now have a quick and reliable means of providing for protection during transport. We have also profited from a couple of welcome side-effects, such as more economical warehousing and tidier work-stations. Protection during transport has improved."
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FOAMplus® reference projects The Storopack approach to improving performance: Integrating operations to achieve the highest levels of productivity at every workstation ▪ Well-grounded: extensive needs analysis▪ Professional: applications engineers prepare a design and detailed action plan▪ Comfort at working: each and every work station is efficient, effective and ergonomic ▪ One-stop supplier: in-house design offices and production facilities
Storopack has extensive experience in integrating FOAMplus® foam cushioning systems into a company’s internal logistics. It’s possible, for example, to supply multiple packing stations with foam components from a central container, ensuring a reliable and trouble-free delivery system. Rather than setting up individual units, Storopack can provide customers with an integrated all-in-one solution. This comprehensive range of services is far superior to the above-market average.
It pays to take a closer look as well when considering a foam padding system for a single, individual work-station: What sort of layout is best from an ergonomic standpoint and which is the most efficient? Because Storopack has an eye for every detail, we are able to offer our customers direct support in systematically putting in place what you need. Our services include setup of all equipment required for foam padding production. We also offer training pro-grams, both for shipping departments and for packing-station operators.
Perfect Protective Packaging
Integration for a manufacturer of cooling and refrigeration appliances
Products:Household appliancesEquipment:One FOAMplus® BagpackerPositive molds for pre-fabricated cushionsProduction rate per packing station:20 seconds per molding (average)Total production:240 shipments / day (average)
Our challenge: The task involves packing of compressors weighing several pounds each. There are a variety of models that often have odd dimensions with parts that jut out. The new packaging solution should reduce the cur-rent number of packaging variants without increasing the costs of inner packaging.
Our solution: Operators working at ergonomically improved packing-stations equipped with the FOAMplus® Bagpacker foam-in-a-bag systems are able to provide for just-in-time production of an appropriate number of upper and lower cushions. In addition, the customer is also able to fabri-cate inner packaging in just the right shapes.
Since FOAMplus® Universal Foam offers an excellent cushioning to weight ratio, total costs for protective packaging remain constant.
What the client has to say: "FOAMplus® offers a real improvement to our protective packaging system. Storopack’s approach affords us more safety, attractive overall costs and greater convenience." 17
FOAMplus® reference projects
Option for Integration:FOAMplus® Barcodes Barcodes for foam cushioning in specific sizes and fill levels are logged in a software database. Once a package arrives at a packing station, the packer registers the labeling information on the shipment and presses a button to activate the release of individual foam bags. At the same time, pictures or videos displayed on the computer screen indicate how the goods and packaging materials should be positioned in the box.
The FOAMplus® Bagpacker includes, if requested, a touchscreen PC and barcode scanner. Alternatively, Storopack service technicians can install the required soft-ware onto an existing PC and scanner system, provided the necessary system requirements are available.
Perfect Protective Packaging
The liquid components polyol and isocyanate combine to produce polyurethane without CFCs (chlorofluorocarbons) or HCFCs (hydrochlorofluorocarbons). The packaging foam expands up to 280 times its liquid volume.
REUSE means …this product can be reused multiple times for its originally intended purpose.
▪ FOAMplus® foam cushioning can be reused for multiple shipments of the same product.
REDUCE means …this product and the associated production process are designed so as to reduce the use of natural resources.
▪ The light weight of the material produces greater fuel efficiencies during transportation. ▪ Universal Foam Technology offering superior strength while minimizing chemical usage - Source Reduction.
RECYCLE means …post-consumer or production waste from this product can be substituted for primary raw materials.
▪ As an element in the general waste stream, FOAMplus® foam is an excellent source of fuel for modern facilities for energy generation through waste products.
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Sustainability & environmental protection
Storopack's own commitment to the responsible handling of our environment and society is derived from the corporate philosophy. Storopack's "Vision & Guidelines" includes formally agreed principles for all Storopack employees. Managers are responsible for the motivation and promotion of the employees so that the awareness of society, culture and the environment continues to develop.
Although resources are necessary for the production of protective packaging, without protective packaging or in the case of too little, or improperly used protective packaging, the transported products will be damaged requiring the new production of these goods. To avoid an impactful waste of resources Storopack advocates the effective and efficient use of protective packaging.