Packaging a TV doesn’t have to be as daunting as it sounds

Using a foam in place system is ideal for applications that require protective void fill, blocking/bracing and cushioning during the shipping process.

One consumer electronics company found that while their exterior packaging showed no signs of shipping damage, opening the box told a different story.

Unit arrived in a box from a specialty shipping service.  The box had no signs of damage on any of its sides.  Cornerboard was used on eight of the edges, held in place with nylon strapping. The original packaging consists of 5 pieces of medium density molded polystyrene.  These parts were badly damaged during shipping because the styrene corner pads appear to be dimensionally incorrect for the size of the box since there is 1”+ of space between the styrene and the top of the box.

IPS Packaging proposed a better solution with a foam in place system.

The time was right to present the prospective customer with a new foam in place solution. The unit was measured and prototype molds were constructed and protective pads were created.  The molds were constructed such that the TV is now 1” further away from the left side of the box to offer more protection in that area and special care was taken during the mold design to iensure that the foam packaging does not contact any of the fragile components on the unit.

The letter “T” was molded into the top pad to illustrate the ability of including an identifying mark to the cushions.  This could be as simple as top and bottom or can include a model number of the unit it will protect. The original box was used to return the sample pack.  The corner board was positioned the same as when it arrived and was held in place with nylon strapping.

Total Packaging Cost Summary

  • Decreased shipping weight
  • Increased damage protection
  • Unique custom inserts allow for a better fit

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