High Tech / Electronics Packaging
Delicate high-end electronic components are precious cargo. Both manufacturers and end-users expect delivery in flawless condition. As such, PPI designs and creates packaging that can withstand the rigors of any shipping container, long-haul truck, loading dock, or warehouse rack. With drop-test expectations as low as 40Gs, we carefully select, prototype and test options until we find the right solution for the application.
We easily adapt to the unique requirements of each client — from electrostatic protection to JIT shipping — while applying our experience to provide the most reliable and cost-effective solution.
Customers of a large high tech company complained that an unacceptable number of products they received did not function upon receipt. The products — printed circuit boards, power supplies and delicate assemblies — did not appear damaged upon visual inspection.
Protective Packaging engineers tested live products using the original packaging materials in its test lab and found that many of the products were experiencing up to 250-750 G-forces. Working with the client's product team, we jointly implemented a product G-force threshold of 40 Gs. Now, before a new package is developed, a seven-page package development questionnaire is completed and evaluated by a Protective Packaging engineer. The engineer will then make design recommendations, build a prototype, drop test, analyze data, make computerized drawings and report findings. Since this system has been implemented zero DOA's due to package performance have been reported.
Medical Device Packaging
PPI has many years of experience working with manufacturers of medical instruments, devices and supplies. As each medical product is the result of years of research and refinement, we design packaging that protects the investment made to bring these products to market.
Our medical clients expect and receive the benefit of our expertise in protecting the most delicate equipment from both expected and unusual hazards. Many of our clients operate in dust-free, clean room settings; we are accustomed to meeting the stringent requirements of these environments. And JIT delivery facilitates quick, safe shipments.
An innovative medical equipment manufacturer needed to transport and protect portable defibrillators. These life-saving devices must be operable in any climate, including extremely cold areas where the units may sit in cold EMS vehicles for extended periods. The equipment specs demanded a minimum temperature of 35° F to prevent freezing of the conductive gel pads.
Protective Packaging engineers designed and developed a portable case with a thermostatically controlled environment to prevent freezing or overheating of the product. The case also has a built-in battery shut-off switch to prevent the loss of starting power to the emergency medical vehicles.
Shipments of weapons, electronics, supplies and other military equipment must anticipate some of the most extreme conditions imaginable — including sandstorms, polar cold, lengthy storage periods, and numerous, time-pressured transfer points.
Creating packaging solutions for these conditions demands an exceptional understanding of materials and packaging technologies. PPI is an experienced supplier to military contractors, with extensive experience regarding military specifications and protocols.
A military branch needed to transport delicate bomb detection devices to multiple locations. The units are fragile and cannot withstand high shock or vibration levels. Exposure to moisture and dust can compromise performance. In addition, ease of moving the units was essential.
Protective Packaging engineers designed and developed mil-spec, dust and moisture resistant cases for the devices. Ergonomically designed to facilitate safe transport, stacking and use, the cases protected these valuable security instruments. The foam was fabricated on our waterjet machines.
In today's finely tuned, just-in-time supply chains, producers of industrial products — from delicate components and sub-assemblies to finished products — cannot afford damage in transit or packaging-related delays. PPI helps clients create reliable, cost-effective packaging for industrial parts and products of every description.
With decades of experience, our engineers have seen every kind of packaging and shipment challenge. We have answers.
A distributor of light bulbs experienced major customer satisfaction problems when a large percentage of eight foot fluorescent bulbs arrived broken. They were shipping fifteen light bulbs per box, using EPS foam to separate the bulbs. When shipped via common carrier, at least 3-5 bulbs per box were breaking in transit.
Protective Packaging engineers evaluated the package and modified the insert design using polyethylene, which provided greater shock absorption and stability. Next we focused on the box. We increased burst strength of the corrugated and selected a five panel folder for greater rigidity and protection. The new design completely eliminated any breakage during shipments.
Custom Packaging for All Industries
Many of our clients are leaders in high tech, medical and military industries, but our work spans the entire economic spectrum, from biotech to consumer products. Each industry brings its own set of unique challenges and expectations. At PPI, we pride ourselves in the ability to engineer cutting-edge solutions for any packaging or shipping objective.
Our engineers bring decades of experience to their work. Their familiarity with a wide range of materials and technologies ensures that each client receives the optimal solution for its situation and constraints.
Gillette Corp was about to make the most important product launch in its company history, The Sensor. Seventy two hours before the product roll-out, Gillette engineers realized that a foam pad 1/8" thick needs to be added to each package for its flagship product.
Gillette called on Protective Packaging to help meet its incredibly important deadline. Protective Packaging worked around the clock to put together staffing, design the part needed and build the cutting tools necessary to produce the foam pad. Within thirty six hours Protective Packaging was shipping millions of foam product to Gillette. Disaster averted.