AirSpeed® HC for Costmetics Supplier

AirSpeed HC

An IPS Packaging specialist approached a cosmetics company to see if they would consider a foam-in-place (FIP) alternative in its distribution center’s repacking area. The customer had been using Sealed Air’s UltraLite low-density foam in conjunction with the Instapak FIP delivery system to protect its heightened skin, body-care and fragrance products.

The Problem

A cosmetics company had been using Sealed Air’s UltraLite low-density foam in conjunction with the Instapak FIP delivery system to protect its tightened skin, body-care and fragrance products.

  • Expensive packaging operation
  • Not sustainable
  • Not protective enough

Our Solution

The cosmetics company made the decision to convert all of their packaging operations to IPS’ Pregis Hybrid Cushioning system, utilizing HC Renew film.

  • Improved packaging solution
  • Improved cost-in-use
  • Sustainable solution
  • Brand image

However, what started off as a review of one aspect of the packing operation, turned into a full blown survey of the entire distribution center-products, applications and operations. This included three separate packaging areas:

  •  repacking
  •  internet fulfillment orders
  •  inline packing.

The end result was an overwhelming decision wherein the customer would benefit the most by converting all packing operations to an IPS Pregis’ Hybrid Cushioning system utilizing HC Renew film. IPS Packaging was able to improve the customers in the following ways:

  • Protective packaging solution
  • Operations
  • Total cost-in-use
  • Sustainable solution
  • Brand image

The first production are put to the test was repacking. Our HC System was trialed against Sealed Air’s 3/16 inch bubble wrap. Upon a close review, the customer discovered they were using so much bubble that they could get better, more cost-effective performance by switching to medium HC.

“Inventory space and labor were minimized because it was no longer necessary to drag bubble rolls across the plant floor to the repacking area.

Another compelling component of the conversion was Renew’s formulation which enabled the company to promote its environmental benefits to its consumers by inserting a card in the box.

One of the package inserts reads:

The HC Renew inflatable cushioning material contained in this box is:

  • Biodegradable(compliant with ASTM D5511-02)
  • Made with significantly less plastic resin than other packaging material
  • 100% recyclable
  • Made with recycled raw material content

Internet Fulfillment: Next up for evaluation and conversion was the internet fulfillment area. In that operation, the customer was using Sealed Air’s Korrvu suspension pack (a structure which combines corrugated and film to suspend and immobilize the product). They had been experiencing multiple problems with this pack: the components take up a fair amount of warehouse space; it’s expensive and the damage rate was too high.

To make the HC/Renew solution even more efficient and viable, autobins with sensors were installed to automatically trigger the HC unit to produce more cushioning material when a low level is reached. By placing the autobins in front of each HC unit, the need to rewind and manually transfer bundles is eliminated.

Inline Packaging: The third area was inline packaging. All products that come down the conveyor belt were previously being packed with Instapak FIP. By moving to a complete change over to Pregis’ AirSpeed HC system, the customer was able to free up floor space previously used to store the chemical drums and avoid questions regarding foam’s environmental impact.

The end result was a total replacement of Sealed Air’s products and equipment with Pregis systems and materials. And, in the words of the customer, there has been “zero damage since the transition.”



IPS Packaging is a leading provider of packaging supplies, packaging equipment and packaging solutions. If you would like to know more about IPS Packaging, call 888.922.1622 or contact our Sales team.

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Posted in Case Studies, Damage Prevention Case Studies