How to choose the right packaging and packaging materials for your logistics?

Article Content

• Introduction to packaging materials
• The importance of correct selection of packaging in logistics
• Types of packaging by design, function, and composition of packaging materials
• Factors influencing the selection of packaging and packaging materials
• Examples of suitable packaging solutions for various situations
• Conclusion and recommendations

The correct selection of packaging and packaging materials plays an extremely important role in the process of ensuring safe and effective transport of goods. The importance of good packaging lies not only in the protection of transported goods but also in the optimization of logistics processes, which can lead to a significant reduction in transport and storage costs.

In today’s environment, where the logistics landscape is constantly evolving and facing many global challenges, as well as a growing emphasis on sustainability, investing in the right packaging is truly a strategic necessity for every company. Lemmacon is an experienced specialist in logistics packaging, tailored to the specific needs of our clients. We realize that there is no single universal solution that fits every situation.

In this article, we will focus on the key factors to consider when selecting packaging materials for logistics. We will also look at the various types of materials and provide an overview of how they can contribute to the efficiency and sustainability of your logistics solutions.

We believe that the knowledge gained from this article will enable you to better navigate the wide range of available options and make informed decisions that will improve not only your logistics but also your company’s overall operational performance.

Introduction to packaging materials

Packaging materials form the invisible yet critical backbone of the supply chain. Their main role is to protect products or structural parts from various influences and ensure that they reach the customer in an undamaged condition.

In today’s world of logistics, however, packaging materials play a much broader role than just protection. The important aspects that specialists in the field are now focusing on include:

• Logistics Optimization: The first point worth mentioning is logistics optimization. Properly designed packaging not only protects products but also allows for more efficient use of available space during transport and storage. In a situation where transport costs are constantly increasing, it is important for companies to have packaging that maximizes the utilized space in trucks, containers, and warehouses. In this way, they can save money and ensure that their goods are delivered efficiently and on time.
• Cost Reduction: The second key factor is cost reduction, which is closely linked to efficient packaging. Proper packaging of products significantly reduces the risk of damage during transport and storage. This means a lower percentage of claims and expenses associated with replacing damaged items.
• Sustainability: The last, but no less important, aspect is sustainability. Nowadays, companies face increasing pressure from regulators and customers who adhere to ecological standards. Currently, for example, the new PPWR (Packaging and Packaging Waste Regulation) standard. This leads to the necessity of switching to ecological packaging materials that are more environmentally friendly (e.g., they are fully recyclable or even made from recycled materials. The concept of returnable packaging (e.g., within a closed logistics loop) is also increasingly applied.

The importance of correct selection of packaging in logistics

The automotive industry, as well as other sectors (such as the electronics and food industries), is characterized by high demands on the quality and safety of its components. These sectors strive to ensure that every individual part meets strict standards that guarantee their reliability and efficiency. However, if packaging materials are chosen inappropriately, serious problems can arise. For example:

1. Damage and Scrap: If the packaging does not provide sufficient protection against various influences, such as impacts, vibrations, and pressure, the risk of rejects increases. This means not only material loss but also increased production costs, as even minor damage can lead to the need to discard parts as waste.
2. Logistics Inefficiency: The use of overly large or unstable packaging results in reduced efficiency in transport and storage. If the packaging does not optimally utilize the capacity of the truck or warehouse, transport and storage costs are unnecessarily increased.
3. Process Slowdown: If the packaging is inconsistent or difficult to handle (e.g., when requiring the removal of old labels), this leads to a slowdown in production and/or dispatch operations. Such delays can negatively affect the company’s overall efficiency and ability to respond to market demand.

Types of packaging by design, function, and composition of packaging materials

In modern logistics, where efficiency and part protection play a key role, we divide packaging into three main, mutually complementary categories:

1. Outer packaging (most often RTP (Reusable Transport Packaging))

This group ensures external protection, stackability, and the overall integrity of the shipment during transport and storage. These are durable packages, generally designed for reuse (Reusable Transport Packaging). Examples include:

• Foldable pallet boxes (KTP, pallet boxes): Large-volume collapsible plastic boxes, often foldable, that save space during return transport (savings up to 79 %). They can also be rented or purchased refurbished, which reduces costs.
• Standard Plastic Boxes (KLT boxes, Euro boxes): Standardized plastic containers of various sizes, designs, and colors, forming the basis of logistics, especially in the automotive industry.
• Metal Pallets (e.g., Gitterboxes): Standardized wire mesh box pallets with clearly defined external dimensions of 1240 x 835 mm (internal dimensions 1200 x 800 mm) produced in several heights (970, 570, and 500 mm). They consist of a metal frame and walls made of wire mesh with a mesh size of 50 x 50 mm. The bottom of the gitterboxes is filled with wooden boards with a planed top side, which are inserted into an L-profile steel frame.

2. Internal storage and fixation materials (typically custom inserts)

These custom packaging materials ensure the precise, stable, and safe storage of individual parts inside the outer packaging (box). Their primary purpose is protection against impacts, vibrations, and scratching of sensitive surfaces. Their design can be varied, for example:

• Plastic Inserts (cartonplast / bubble plastic): Durable, washable, and lightweight materials, ideal for creating precise grids or dividers. Also suitable for ESD protection of sensitive electronics.
• Textile and Foam Systems: Provide soft padding and fixation. These include, for example, the sliding Lemmaroll system (a combination of textile and aluminum tubes for hanging pockets) or foam combs (e.g., made of high-density cross-linked foam).
• Multi-layer Trays: Complex solutions combining several materials (bubble plastic, polyurethane foam, non-woven textile, foam blocks) for maximum protection of fragile parts, such as bumpers.

3. Auxiliary and identification materials

These are not directly packaging materials. However, they are a very important accessory that no packaging can do without today. They ensure the smoothness of logistics processes, easy maintenance, or identification and tracking. This may include:

• LemmaTag: Smart self-adhesive backings that allow for easy peeling off and re-affixing of logistics labels. This streamlines packaging washing and eliminates “false rejects” during automated reading of poorly affixed labels.
• Tracking Systems (LemmaTrack): Technology for online tracking of the location and status of packaging units, helping to prevent loss and damage.
• Wheels, pockets and label holders, handles or profiles.

Factors influencing the selection of packaging and packaging materials

To select the correct packaging, you must consider a number of criteria, such as:

Product type

• Sensitivity to Electrostatic Discharge (ESD): Requires ESD treatment of the material, as is the case with bubble plastic for electronics.
• Fragility/Surface Sensitivity: Requires soft internal padding, such as polyurethane foam, Miralon, or textile (Astonika, Evolon).
• Shape and Size: Affects the dimensions of the packaging and the need for custom internal dividers/inserts that perfectly fix the part or product.

Method of transport

• Long-distance vs. Regional: Long-distance and international transport (e.g., maritime) requires more robust and durable transport packaging and used packaging materials than short domestic deliveries.
• Stacking: The packaging must withstand the load when stacking (e.g., pallets with a load capacity of up to 1,450 kg with 1+5 stacking).
• Industry Requirements (e.g., Automotive Industry): Often requires the use of standardized boxes, such as KTP, VW pallets or BMW pallets.

Protection and preservation requirements

• Impact and Vibration: Requires a combination of hard outer packaging (pallet box or metal pallets) and cushioning inner filling (foam, textile pockets, etc.).
• Cleanliness: For highly sensitive parts, it is key that the packaging is easy to maintain and suitable for industrial washing (Lemmacon offers packaging cleaning without chemicals).
• Reusability: Returnable packaging (RTP) ensures long-term protection and repeated use, which reduces the financial demands of logistics.

Examples of suitable packaging solutions for various situations

Conclusion and recommendations

Effective logistics today is no longer based only on price, but primarily on the quality, reliability, and sustainability of the packaging. Investing in custom solutions and returnable packaging (RTP) may require higher initial costs, but in the long term, it leads to significant savings (reduction of rejects, logistics optimization, better transport utilization, etc.).

As Lemmacon s.r.o., we offer comprehensive service and consulting from our own custom packaging development, through optimization and production, to additional services such as packaging rental or tracking using LemmaTrack.

Do you want to optimize your logistics costs and ensure 100% protection for your parts or products? We will be happy to design the optimal custom packaging solution for you. Contact us for a free consultation.