Collapsible Returnable Engine Transport Rack
New Packaging Development & Cost Optimization
Client Needs
Ship a new 2-cylinder gas engine to multiple OEM customers; replace heavy, costly individual wooden crates with consistent packaging as freight costs and damage rates rose.
The Challenge
Design a modular returnable rack holding six engines that reduces freight cost per engine, protects high-value components, works with forklift and crane, and meets safety/ergonomics/stacking for cross-country transport.
Our Approach
- Collected engine dimensions, CoG, mounting points
- Mapped handling sequences
- Developed 3D rack concepts (steel frames, adjustable cradles, polyurethane contact points)
- Ran FEA and a prototype
- Conducted vibration/tilt/drop tests and a pilot shipment
- Added foldable side posts
The Impact
- Load density +50% (six engines/rack vs four)
- Freight cost -22% per engine
- Rliminated wood waste
- Zero in-transit damage across first 5,000 units
- Standardized globally across three plants
Let’s Talk Efficiency Gains
Want to reduce production costs, increase throughput, or optimize your packaging line? Let’s connect.
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