Design and production of complete packaging for Fiat Panda car parts
Case Study
Client: Leading Croatian Manufacturer of Components for the Automotive Industry
The client for this project was our long-term customer, who is also one of our largest clients in Croatia. The company specialises in the development and production of parts from various materials for car exteriors and interiors, and is one of the leading companies in this segment in Eastern Europe. The firm’s key products include dashboard and door panels, handles, carpets, bonnets, sun visors, spoilers, deflectors, bumpers, diffusers, etc.
Beyond its operations in Croatia, the entire international group also includes several smaller companies and factories in Romania, Hungary, Serbia, and Russia. The client exports over 90% of its production to customers in Western Europe, including brands such as Renault, Stellantis, and Peugeot.
Inquiry: Complete Packaging for Safe Storage and Logistics of Thousands of Auto Parts
The above-mentioned long-term client requested packaging for more than 5,500 parts for Fiat Panda vehicles.
The following four types were involved:
- Front Wheel Arch Trim – left and right versions
- Rear Wheel Trim Door – left and right versions
- Rear Wheel Arch Trim – left and right versions
- Sill Molding – left and right versions
The automotive industry is characterized by high demands for quality and safety of components, which must be protected during production, storage, and transportation. This requires the use of effective packaging technologies that ensure the integrity of the components and minimize the risk of damage.
Proper packaging:
- optimizes logistics,
- improves component protection,
- reduces packaging costs.
Chosen Solution: Pallet Boxes for Outer Packaging, Lemmaroll Sliding System, Textile and Foam Inserts Inside
How did we handle the packaging of the individual parts? Let’s break down each type separately.
Part: Front Wheel Arch Trim (left and right versions)
For this part, we designed textile and foam inserts that perfectly match the shape and size of the part, providing protection against impacts, vibrations, and pressure during transport. At the same time, they prevent the parts from moving inside the box.
As the outer packaging, we used a pallet box with dimensions of 1,200 x 1,000 x 810 mm (length x width x height). For the internal part, we used our Lemmaroll sliding textile system, which allows safe placement of a larger number of parts in the box. Each box could hold 22 of these parts.
We placed bubble wrap at the bottom of the box, onto which we glued a thin foam layer to prevent damage when parts come into contact with the bottom.
The pockets of the sliding system were sewn from a combination of Evolon nonwoven fabric (100 g/m²) on the outside and 3 mm thick Miralon for internal padding. Each pocket was also reinforced with PVC stiffeners.
The Lemmaroll system was attached to the edges of the box and also in the middle using aluminum tubes, which makes opening and closing easier.
The boxes were equipped with label holders and client-required stickers.
Part: Rear Wheel Trim Door (left and right versions)
As the outer packaging, we again selected a pallet box, this time with a shorter sleeve. The external dimensions were 1,200 x 1,000 x 790 mm (length x width x height).
Inside, the same Lemmaroll sliding system was used, allowing 66 units of the part to fit into the box.
Part: Rear Wheel Arch Trim (left and right versions)
The choice of outer packaging and internal system was the same as in the previous cases: pallet box and Lemmaroll system with pockets made from a combination of Evolon and Miralon. The sleeve height of the pallet box was 860 mm. The base was the same as before. Each box could hold 51 of these parts.
Part: Sill Molding (left and right versions)
This was the largest part of the project. We packed 2,544 right and the same number of left Sill Molding parts.
For this part, the client wanted to use outer packaging from their own stock. The boxes were metal, each with dimensions of 1,950 x 1,150 x 1,070 mm (length x width x height). Our task was to supply only the internal insert.
Inside, the foam combs consisted of an L-shaped plastic profile and foam. The plastic profiles were made from black bubble wrap with a surface weight of 1,000 g/m². Foam combs made from cross-linked foam with a density of 45 kg/m³ were glued onto them and further secured with turbo screws.
Client operators filled the right and left sides of the box with these combs and then inserted the parts between them. To help with orientation and to avoid mixing up the combs for each side, we differentiated each type by color: combs for one side were white, for the other black.
Each layer could hold 5 parts. Each box could be stacked with 6 layers, so the capacity was 30 parts per box.
Result: 100% Part Protection, Maximum Client Satisfaction, and a New Order for the Same Packaging
The total production took us 740 hours. Thanks to the designed packaging, there was no damage to components during production and logistics. The client thus avoided delays in part deliveries, increased costs for replacing damaged parts, and ultimately customer dissatisfaction.
As a result, our client was also satisfied and subsequently placed a new order for the production of hundreds more packaging units for all four mentioned parts.
