Customized plastic containers from Gamma-Wopla

Cartons were previously used to deliver over 380 million copies a year. However, the disadvantages and associated handling problems increased and became a serious cost problem. Jean Paul Hivoux, Operations Director of the Presstalis Group, explains that due to the weight of the paper, the cartons wear out quickly and enormous amounts of waste accumulate every day. He adds: "There is little space at the retail outlets. Therefore, in the metropolis of Paris, especially in the narrow and popular tourist districts, the flair of the city is disturbed by the large quantities of empty cartons on the sidewalks."

Logistical challenge in the metropolis

Too much packaging material was only used once and thrown away every day. This was recognized as a key problem. "We quickly realized," Jean-Paul Hivoux continues, "that finding an adequate solution as an alternative to cardboard boxes would be a major challenge, as it affected the entire distribution process."

This begins with the delivery of the newspapers and magazines to the main distribution center, continues with sorting to the recipients - the sales outlets - and the relevant distribution hubs and ends with packing the optimum number of items in correctly dimensioned transport containers. According to Hivoux, further challenges of the conversion project were the integration of the containers into the recently installed picking system, the labeling of the containers for seamless tracking on the outward and return journey and the logistical specifications for transport. "The physical strain on the employees due to the weight and the simultaneous optimization of costs also presented us with complex tasks," says Jean Paul Hivoux, describing the situation.

Delivery in French

With 12 branches and 100 distributors, Presstalis is the main player for the daily press distribution service in France. More than 3,000 daily press titles, magazines, multimedia products and encyclopaedias with 1.5 million copies are delivered daily to 27,000 sales outlets in France (around 70 percent of the national press market) and in around 100 countries worldwide.

The solution: the customized, sustainable plastic container

150,000 containers are in circulation.

The company took a thorough look at this problem. After detailed analysis, a specification sheet was drawn up and several suppliers were contacted. Gamma-Wopla from Belgium quickly emerged as the best partner. "They listened very carefully and were immediately willing to respond to our demands and requirements. We then worked hand in hand to develop the best end product," says Jean-Paul Hivoux, describing the process.

Container holds two stacks of magazines

A special plastic container was custom-designed, taking into account all of Presstalis' requirements, in order to meet all of the points in the specifications. An injection mold was developed and several containers were tested by the users. Several adjustments were necessary until the ideal product was finally developed. Above all, it was important to optimize the weight of the containers to better prevent physical strain on employees in the future. Thanks to its compact dimensions of 495 x 380 x 177.5 millimetres, the Presstalis plastic container fits into the fully automated picking system. Added to this is the large filling capacity, as the container can hold two stacks of magazines.

Stacks of six containers facilitate transportation

Gamma-Wopla has also equipped its containers with a special lid. This allows six filled containers to be stacked, which makes transportation easier, and the magazines, some of which are of high quality, are optimally protected from damage or rain. The containers can also be nested, so that up to 228 empty containers can fit on one pallet for return transportation. With the colors grey and orange, the containers correspond to the corporate identity and are provided with your own company logo.

The containers can be nested, making it easier to transport the empties back.

This means they can be identified immediately at the points of sale and distribution centers. "The nestability offers us additional efficiency when returning the empties. And the fact that we can implement our sustainability policy with the containers from Gamma-Wopla, which are made from 100% recycled high-quality raw materials, is particularly pleasing," emphasizes Jean-Paul Hivoux.

Extremely resistant labels Traceability of the containers is an essential condition for controlling the availability, location and return of the containers. To prevent the labels from being torn or damaged, highly resistant barcode labels were chosen that can withstand impact, friction, high-pressure washing, sub-zero temperatures and UV radiation. The printing was applied from below on the back so that it is covered by the label itself and protected from damage as a marker.

The positive effects of the switch from cardboard boxes to plastic containers from Gamma-Wopla affect the entire supply chain. Presstalis now has a total of 150,000 plastic containers in circulation at all eight industrial sites, 14,000 depots, 110 distribution hubs and 10,000 distributors. "We have our logistics chain completely under control, have an overview of stock levels and can guarantee 100% delivery. It was a mammoth project, but it was feasible thanks to the collaboration with Gamma-Wopla and it was worth it in every respect," concludes Jean-Paul Hinoux.

Beate Jahoda

Contact:

Presstalis 75931 Paris cedex 19, France Tel.: 00 33 / 1 / 49 28 70 00 E-Mail:

Gamma-Wopla 7700 Mouscron, Belgium Tel.: 00 32 / 56 85 20 85 E-mail: [email protected] www.gamma-wopla.com