How small changes drive big impact – Multi-Depth Creasing
Over the past three decades, I have written protocols, developed equipment, and supported the construction of three e-commerce supply chain testing laboratories. This has enabled me to conducted some 5,000+ tests for e-commerce packaging, many of which involved focused studies into best practices for structural design.
In this one particular study I’m about to share, I tested multiple cases from around eight different manufacturing locations, with the aim to check compression in all orientations and develop a common performance specification for loose loaded parcels.
The box in question, was a multi-depth FEFCO 0201 and with the growing importance of right-sizing for sustainability, optimisation, and compliance with PPWR legislation, this style of box is becoming increasingly attractive to many online retailers.
Testing started normally, with length and width being very close from the different manufacturing locations, but during the depth compression tests, results varied significantly, with the highest reading being more than twice that of the lowest.
Whilst I had already carried out a study in multi-depth scores and how they affect drop tests or material choice, I was surprised to discover just how much the results could be affected by such a minor and somewhat overlooked detail.
I discovered that not only did the three creasing wheel types provided significantly different results, but that even when using the same type of creasing wheel, the pressure used to apply them could make a substantial difference. This is something a designer might not necessarily have full control over in manufacturing, but it is a vital detail that can affect both sustainability and costs for the customer. Just to think, that a 100% increase in compression could be achieved from adjusting the corrugator pressure settings by less than 1mm and using a specific type of creasing wheel.
Here’s the tricky part though, whilst the lower pressure in the score leads to higher compression result, this can make the crease harder to fold, potentially causing issues for packers in operations, so its important to find the sweet spot and what works for your situation.
So here is the key takeaway: whether you are a designer, manufacturing supplier or the customer purchasing this style of box, its important to understand the significant impact these small details can have on your sustainability or cost optimisation projects.
