When a consumer returns a new television or other electronic item back to the store where it was purchased, the product frequently doesn’t go back to the shelf for resale. Those returns (and also those that are broken or damaged), frequently find their way to one of several refurbishment companies. Retailers rely on them to repackage and sometimes recondition the product so that it meets specifications for sale as a new or used item.2333343004_57017a11bd_z

Traditionally, these refurbishers have used protective products such as expanded polystyrene, die-cut corrugated foam inserts, and other end caps made from foam or engineered pulp, to protect the product throughout the distribution cycle. Many of these traditional solutions are bulky to store and take up valuable inventory space.

Pregis was approached by a distributor partner who had a relationship with a major electronics refurbisher. They were looking for a way to differentiate their packaging and also reduce inventory space. They had also experienced some failures with foam end caps. (They did not friction fit tightly around the product and after several drops would fail, resulting in new product damage.)

Pregis’ ChamberPak design facility was engaged to create a solution which could accommodate television sizes ranging from 32- to 60-plus inches. The end result was a suspension corner pack that is manufactured in six different sizes. (Additionally, there is a U-channel that is placed around center edges.)

In situations where the refurbisher didn’t have to use the OEM carton, a smaller size was designed, further reducing material usage and cost. Because ChamberPak is more flexible than rigid end caps, this means that it easily adapts to a tighter fit.
Suspension corner pack