Initial customer feedback indicates an up to 75% cost reduction and/or improved load containment when compared to traditional secondary packaging methods.
The new HexStack packaging system features a single layer of Hexacomb honeycomb material that’s custom-die-cut to accommodate the specific bottle neck. The pad is laid on top of a layer of bottles, with the closures and necks inserted into the die cuts.
The die-cut orifice surrounds the bottle neck and rests on the shoulder, thereby immobilising the container. A secondary process can also punch-die-cut a shallower, wider circular channel under the hole to accommodate an optional carrying handle ring.
For those bottle designs with a concave base, the slightly protruding closure above the die-cut orifice can nest into the base of the container above it, further stabilising the load.
The final step in the pallet load unitising process is shrink-wrapping. Using this method, larger liquid bottles can typically be stacked three layers high for transport and retail display.
Hexacomb HexStack pads are made primarily from renewable wood fibres engineered into a proprietary honeycomb configuration. The material fabricates easily to address custom requirements and is ideal for pallet loads requiring strength and lightweight attributes.
HexStack pads contain recycled content which helps support brand owner environmental initiatives and are recyclable in corrugated recycling streams available in local communities.
Source: Hexacomb Corporation
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