Lightweight Thermoformed Trays for Battery Pack Transport
New Packaging Development & Cost Optimization
Client Needs
Transport solution for completed battery packs to reduce freight costs, improve load efficiency, and maintain protection while minimizing reusable-packaging CapEx.
The Challenge
Traditional trays heavy/inefficient, limiting packs per truckload; reduce fleet CapEx without compromising protection; maintain integrity of sensitive battery packs.
Our Approach
- Designed twin-sheet thermoformed trays for strength, durability, and weight reduction.
- Optimized dimensions to maximize truckload utilization while maintaining protection.
The Impact
- 18% increase in truckload capacity (up to 4 additional packs/shipment)
- Saved thousands of pounds of transport weight
- Reduced packaging-fleet CapEx
Let’s Talk Efficiency Gains
Want to reduce production costs, increase throughput, or optimize your packaging line? Let’s connect.
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