Single-Use Thermoformed Tray for Connecting Rod Housings

New Packaging Development & Quality Remediation

Client Needs

Cost-effective protective packaging for high-volume precision connecting rod housings with tight-tolerance machined surfaces vulnerable to corrosion and nicks (bulk boxes + loose foam gave a 5-7% rework rate).

The Challenge

Expendable system that maintains separation between machined surfaces, prevents corrosion in short-term storage/domestic shipment, stays within unit-cost limits, and nests/stacks/disposes easily.

Our Approach

  • Designed a thin-gauge HDPE thermoformed tray cradling parts at non-critical surfaces
  • Specified VCI coating and VCI-lined poly bag 
  • Optimized thickness via trials
  • Ran drop/vibration/stack tests.

The Impact

  • Corrosion-related rejects reduced to <1%.
  • Packaging cost per part cut 30% vs foam/corrugated.
  • Packaging density improved 40%, lowering freight.
  • Standardized across multiple machined components.

Let’s Talk Efficiency Gains

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

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