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Returnable Bulk Containers with Rigid Dividers are an Ideal Solution to Protect Odd Sized Components

DS Smith Plastics France Assists Yanfeng Automotive Interiors with a Design to safely transport glove-compartment components across their entire supply chain.

The challenge

Yanfeng Automotive Interiors―the world’s largest supplier of auto interiors―was in search of a returnable bulk packaging solution to transport their automotive glove compartment boxes between sub-assembly plants. The returnable packaging would transport glove compartment boxes between the Yanfeng manufacturing sites, suppliers of the injection moulded components and locking mechanisms. The returnable packaging needed to be fit to carry all glove compartment components, offer loading optimisation of components to trucks and reduce of the overall logistics and transportation costs.

The approach

For the task, Yanfeng contacted DS Smith Plastics, Extruded Products in France, a successful partner on previous projects. DS Smith Plastics proposed the use of their AkyPak® Classic polypropylene returnable container with a rigid divider and layer pads cut to fit and protect a set of components with odd shapes and sizes.

DS Smith Plastics’ AkyPak Classic foldable container is a three-piece returnable solution with excellent weight to strength ratio, high impact resistance and offers optimised return logistics with folding sleeves, stackable lids and nestable pallets. The latter would certainly reduce their logistics and transportation costs.

The result

To meet and exceed customer requirements, the suggested solution was designed with V3 lids that extends the internal height of each container lid by 10mm. This option increased the load capacity of each container allowing for and additional third layer of glove compartment boxes, accommodating 8 more components while maintaining the same external height of 1000mm.

DS Smith Plastics demonstrated not only the capacity to provide a high-performance returnable packaging solution, but also considered the customer’s challenges across its entire supply chain including customer’s returnable logistics’ loop.

About Yanfeng Automotive Interiors

Yanfeng (YFAI) is a global leader in automotive interiors. Headquartered in Shanghai, the company has approximately 110 manufacturing plants and technical centers in 20 countries and more than 33,000 employees globally. They design, develop and manufacture automotive interior components for all automakers. Established in 2015, Yanfeng Automotive Interiors is a joint venture between Yanfeng, one of the largest automotive suppliers in China and Adient, the global leader in automotive seating.

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