This solution came about after our customer requested a unique SCHAEFGUARD solution for shipping their automotive trim parts. They tasked our design staff to come up with a way to hold multiple layers of parts in the NF241505.AS tote.
However, there was a catch. The customer wanted to ensure that the internal dunnage layers would not be lost during their processes — so the customer requested us to make them non-removable. Additionally, they did not want the dunnage layers tethered with nylon straps or cords.
With these parameters in mind, our designers came up with the perfect solution. For the top layer of dunnage, we added a hinge — but we also needed to account for the bottom layer of parts. To keep the top layer out of the way when removing the bottom layer of parts, we installed magnets into the dunnage and small tin plates secured to the inside tote walls.
This design uses corrugated plastic for the dunnage trays and XLPE foam to secure the parts in place. We riveted metal plates to the inside tote walls. Magnets in side-sewn vinyl pouches hold the top layer in place. With this design, we met our customer’s challenge by engineering an inexpensive, reusable solution.
Nothing excites our design team like a challenge. Every project gives us a chance to create innovative solutions to our customers’ problems. If that requires new materials or new ways to use our standard materials, we will develop one-of-a-kind custom products that make our clients’ workflows easier.