16th Jan 2001: Netlon meets a tough new challenge

Netlon polymeric protective sleeving mesh was recently used by a bathroom ceramics manufacturer in a trial to reduce transit damage costs. It passed with flying colours and was adopted as the permanent solution.

Because of their long distribution chain, bathroom ceramics are particularly susceptible to damage caused in transit -- damage which can result both in frayed tempers and in reduced profits. One leading manufacturer recently decided to tackle this problem by asking its logistics manager to research a more effective packaging medium for WC pans and basins than the sticky foam pads and plastic shrink-wrap which were then the norm. Having seen plastic mesh used successfully in other packaging applications, the logistics manager approached Netlon Limited, the leading producer of plastic mesh-based products, for a solution.

The problem

Bathroom ceramics travel from manufacturer, to distributor, to merchant, to plumber, and finally to the homeowner. No matter whereabouts in the chain damage occurs, the product is returned to the manufacturer. Returns are costly, not only in financial terms - each damaged item must be discarded and a new one supplied - but also in terms of relationships with the various members of the chain. Delays of several days, or even weeks, before replacements can be supplied are not unusual (particularly for non-standard models), bringing the potential for frustration at all stages. Clearly, it makes sound commercial sense to keep returns to a minimum.

The requirement

A new protection product was needed which could be cut to size in the most cost-effective manner and would drastically reduce the number of components damaged. It had to be lightweight and non-bulky, accommodate a layer of shrink-wrap over the top, and look professional, to demonstrate to customers the high level of protection.

The solution

Made from chemically resistant polyethylene, Netlon packaging products can be manufactured in any mesh or sleeve configuration, size and colour, with particular properties, such as specific chemical resistance, if required. Netlon also manufactures two standard packaging meshes, Universal Protective Sleeving and Premier Protective Sleeving,

For this project, three new protective sleeve products were developed which were able to protect the full range of ceramic components. The sleeves met all the manufacturer's requirements and had excellent stretch capability, which meant that a minimum number of sleeve sizes could protect a vast range of components. Netlon staff worked closely with the manufacturer to maximise cost-effectiveness, optimising lengths, colours, packaging and labelling.

The result

Within one month of the introduction of the Netlon sleeving, the manufacturer saw a dramatic reduction in the number of components returned because of damage. As an added benefit, sales to small builders increased, such was their confidence that the products would arrive undamaged.

Although the sleeving proved marginally more expensive than sticky pads in the short term, it quickly paid for itself through the reduced number of returns. Indeed, after a year of using the product, the ceramics manufacturer's management team confirmed that significant savings had been made as a direct result of the change in packaging.