All in one

The PackReport magazine reports in its February issue about an innovative packaging solution for exhaust hoods from DS Smith. Read the full article below. 

High-performance exhaust hoods not only ensure a fresh indoor climate without vapours, but are also eye-catchingly good to look at. Every kitchen is different – just as well exhaust hoods are constructed with just as much individualism. High-quality materials and modern design are what distinguish these devices. However, the individual construction designs and high-quality materials make great demands of the packaging.

In the development of such packaging concepts a 360-degree perspective as well as innovativeness and industry expertise are required. The specialist for corrugated cardboard packaging, DS Smith, has proven all of this with its development of a standardised uniform packaging – true to the motto 'the power of less'. Many different device shapes and sizes can now be optimally stored and safety transported in a single, process-optimised packaging.

The free-hanging exhaust hood gives every kitchen a specific look as a visual eye-catcher. The requirements of their functionality and, in particular, design are just as specific. The consequence is a great variety of device shapes and sizes as well as materials used. The width of the various exhaust hoods can vary by up to 90 centimetres. The materials used range from stainless steel and aluminium to glass. Due to the great variance in functionality and design as well as quality of materials BSH Bosch and Siemens Hausgeräte GmbH, Europe's largest household goods manufacturer, has previously had to rely on a great variety of packaging solutions.

A separate packaging was used for every device width according to the dimensions of the exhaust hood. The interior was usually filled with styrofoam padding, which adapted to the respective device shape. The various models of the ‘Slimline-Walmdach’-chimneys, box chimneys and stepped chimneys were stored in packaging standing on the visible face and secured with styrofoam padding on the side. This led to the possibility of the viewing hood being stretched if knocked on the ground due to three-point loading as a result of the weight of the exhaust and therefore had to be supported with additional packaging parts. All other design varieties were able to be entirely transported lay on their backs and were protected by stryofoam plates.

The number of individual packaging parts continuously grew with every change of the exhaust hood design. The styrofoam padding and plates not only required storage capacity, personnel on the assembly line also had to be trained for the individual pieces of packaging and could therefore not be arbitrarily put to use. Furthermore, the packaging was only filled with the finished device after fitting.

With standardised uniform packaging DS Smith l Packaging Division D-A-CH, together with BSH, have been able to develop an intelligent concept, meeting the high requirements of the product in every way.

All in one – standardised uniform packaging

In the innovative corrugated cardboard solution for exhaust hoods, the ventilation box with a fan motor - the only standard part installed in all devices - becomes the supporting part of the packaging. The viewing hood, the shape of which varies a great deal depending on the design, hovers freely in the packaging on the other hand. "With this concept we achieve an independence of shape and width of the devices. We have thereby reduced the number of packaging parts for our customers from approx. 150 to 26," says Michael Lamprecht, Sales & Marketing Director at DS Smith l Packaging Division D-A-CH. At the same time, the packaging now also serves as a cross member in production. The device is already fitted during packaging and no longer lifted into the packaging with its full weight afterwards.This clever solution therefore not only ensures reliable protection of the high-quality products, but also efficient and economical processes across the entire supply cycle.

  The standardised uniform packaging is made up of a covering box and three supporting boxes pre-fitted with tube bonding. Two wooden slats ensure the optimum purchase and allow a seamless internal transportation with clamp trucks. The concept reduces the storage volume and the number of packaging parts to a minimum and guarantees simple handling. The packaging can be setup in just a few steps. Subsequently, the ventilation box with a fan motor is pushed into its fixing and all further parts are fitted to it. This means the device only leans on the screwing of the ventilation box and the viewing hood hovers freely in the packaging - without any contact to the outer walls. This protects against transportation damage, for example, due to knocks, but also makes the packaging independent of the shape and width of the device. The solution is set out for the largest device; all smaller devices can also be packaged easily and safely with it.

Less is more – the power of less

The successful development and implementation of the packaging concept for the demanding products of BSH is based on the proven key to success of DS Smith: less complexity and more efficiency, less waste and more recycling, less material and more effectiveness, less costs and more success - in short: the power of less. The basic requirement is a complete analysis of the process steps of the customer. This is how the packaging expert ensures its products achieve more at the decisive moment with less effort. "There are starting points in many positions in order to optimise the process and therefore the result," says Michael Lamprecht.The full service packaging supplier DS Smith uses its many years of experience and its expert knowledge for the optimisation of the supply cycle of its customers: "With our complete approach we offer solutions that help our customers to be more successful," explains Michael Lamprecht.

For DS Smith, the 360-degree view begins in the production hall of the customer and spans from the analysis and collection of the individual process steps to the storage and transportation situation. This is decisive in order to allow the static and dynamic loads of the packaging to flow into the design and the choice of material.The results of the detailed analyses are packaging concepts optimally adjusted to the specific properties of the product and the individual process steps of the customer. DS Smith has also achieved this in the packaging solution for the BSH exhaust hoods. "The standardised uniform packaging for exhaust hoods once again confirms that we are on the right path with our approach of reducing the complexity for our customers. This allows us to achieve the best-possible result for our customers and reduce their risk," says Michael Lamprecht.