Returnable Rack Program for Architectural Glass

Cost Optimization, New Packaging Development, & Sustainability

Client Needs

Reduce the >$22M spent annually on wood and expendable packaging for shipments of large architectural (thermopane) glass panels.

The Challenge

Extremely large panels packed while the seal is still curing (must stay flat); special handling for tipping hazards during shipping.

Our Approach

  • Surveyed client job sites;
  • Analyzed panel sizes to define requirements; 
  • Developed a freight-friendly returnable rack platform with 12 custom rack sizes for the most common panels.

The Impact

  • Standard returnable-rack program capable of replacing 90% of expendable (wood) packaging 
  • Projected savings of $12M/yr by year three

Let’s Talk Efficiency Gains

Want to reduce production costs, increase throughput, or optimize your packaging line? Let’s connect.

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