Foldable large load carrier reduces costs for empty transport

Gestamp develops and manufactures steel body, chassis and mechanical components for the international automotive industry. With around 1,450 employees, the plant in Bielefeld is the Gestamp Group's largest production site. The 200,000 square meter site is a hive of activity and the plant's internal logistics areas are often used to capacity. Fast and uncomplicated storage and retrieval of goods requires cross-company planning and good ideas. An intelligent solution has now been found for the shipping and storage of hollow steel frames. The curved frames with a length of around 850 millimetres are produced by a Gestamp sister company in Manchester, England, and delivered to Bielefeld for further processing into integral frames for wishbones.

"The packaging solution from Schoeller Allibert has made our logistics processes more efficient. The payback period for the investment is less than a year."Frank Brindöpke, Head of Logistics Planning, Gestamp Umformtechnik

Until 2015, Gestamp Umformtechnik packed the components in steel mesh boxes measuring 1,240 × 835 millimetres. However, the temporary storage of the rigid mesh boxes took up a lot of space and at the same time the empty transportation of the boxes to England caused high costs. There was also a need for optimization in the area of product protection, as the hollow steel frames were exposed to the weather due to the open and unprotected outdoor storage, resulting in corrosion.

Unnecessary empties reduced

More space and better protection for the hollow steel frames from Gestamp Umformtechnik.

Schoeller Allibert provided a remedy with a better alternative to the steel mesh box: the Magnum Optimum plastic container measuring 1,200 × 1,000 × 975 millimetres. The transport packaging is the only foldable large load carrier available on the market with a certified load capacity of 750 kilograms and is therefore just as stable as a pallet cage, but much easier to handle thanks to its lower tare weight. With Magnum Optimum, Gestamp Umformtechnik was able to permanently reduce unnecessary empties during storage and delivery to less than a third of the previous volume. Valuable space was gained at the Bielefeld plant and the cost of transporting empties to England was significantly reduced. Each truck can now transport 208 folded containers and the number of empty runs has been greatly reduced.

More products on the truck

Another advantage of the new packaging solution is the larger capacity of the robust plastic containers. With the lattice boxes, 78 hollow steel frames could be transported; Magnum Optimum offers enough space for 98 units. Whereas Gestamp Umformtechnik used to transport 60 lattice boxes or 4,680 hollow steel frames in one truckload, today it transports 52 plastic containers with a capacity of 5,096.

When folded, the plastic containers from Schoeller Allibert take up two thirds less space than mesh boxes.

Soiling and rust on the components are also avoided from now on. Thanks to the closed side walls and lids, the containers ensure good dust protection. They can also be used for outdoor storage without any problems, as the drainage openings in the closed base of the Schoeller-Allibert packaging provide additional protection against moisture.

Convenient handling

The durable reusable transport containers are very easy to handle. They can be assembled and disassembled in a flash without having to follow a specific order when folding. The closures are easy to operate and smooth surfaces facilitate cleaning and reduce the risk of injury. Magnum Optimum also scores points with its greater flexibility compared to mesh boxes. If Gestamp Umformtechnik wants to use the packaging for other products, the height can be adjusted at any time using the Optiframe attachable frame.

Over the next two years, further suppliers to the Bielefeld production facility are to be converted to the new packaging solution.

Dr. Matthias Schweizer