If you thought RollerPlast only re-imagined crates and trays, think again. When it comes down to it, the RollerPlast team isn’t driven by outcomes. We’re driven by creating solutions that just happen to make your warehousing challenges easier.
Sometimes that means we’re reinventing your crates and totes—but not always. Recently, a client came to us with a new challenge: pallets.
HOW OUTDATED PALLET DESIGN NEGATIVELY IMPACTED OUR CLIENT’S WAREHOUSE
One client, two problems. The first challenge: condensation in cold storage facilities.
In this client’s facility, condensation became a major issue as it dripped down into the shuttle systems and power cables, which often caused an increase in downtime due to the extra daily maintenance required. In extreme cases, the condensation would trigger automatic system shutdowns to avoid damaging the shuttles.
The second challenge came from the difference in pallet sizes in Asia (where they were importing large pallets of goods from) and America. The pallet size difference was costing an exorbitant amount in additional labor to repalletize the products upon receipt.
OUR SOLUTION TO THE PALLET CHALLENGE
Creating solutions always starts with collaboration. The RollerPlast team worked closely with our client to develop a custom tray that nested the pallets and retained up to 50 litres of water. Once the 50-litre threshold is reached, excess water could be released from the shuttle through dedicated drain holes. This effectively keeps condensation from damaging equipment.
Regarding the second challenge, we developed a custom-sized pallet that boosts productivity and lowers operating costs by nesting the non-standard imported pallets without having to repalletize them.
HOW A NEW PALLET DESIGN IMPROVED WAREHOUSE FUNCTION
It’s easy to overlook the impact of pallets on warehouse efficiency and functionality. But just as with crates and totes, pallets can have a major impact, and the old ways of doing things don’t always cut it in a modern warehouse. The new pallet solutions created by the RollerPlast team to combat the condensation issues have improved operational efficiency, reduced downtime, lowered maintenance costs, and lowered labour costs. And the nest created for the non-standard imported pallets has allowed our client to bid on a sizable project in the Asian market, as they can now offer flexible, custom-sized manufacturing at a reasonable MOQ.
Sometimes, you don’t need to completely reinvent the wheel to make significant positive impacts on your business; you just need to make some modifications to your pallets.
FREQUENTLY ASKED QUESTIONS
DOES ROLLERPLAST ONLY DESIGN CRATES AND TOTES?
No. RollerPlast specializes in solving warehousing challenges, which sometimes means reinventing crates and totes and sometimes means something else entirely. In this case, a client came to us with a pallet problem, and we designed custom pallet solutions.
HOW CAN PALLET DESIGN SOLVE CONDENSATION PROBLEMS IN COLD STORAGE?
Condensation in cold storage can drip into shuttle systems and onto power cables, increasing downtime and maintenance and, in extreme cases, triggering automatic system shutdowns. RollerPlast solved this for a client by developing a custom tray that nests the pallets and holds up to 50 litres of water. Once that threshold is reached, excess water drains away from the shuttle through dedicated drain holes, keeping condensation off the equipment.
HOW CAN CUSTOM PALLET SIZING SOLVE THE PROBLEM OF MISMATCHED PALLET SIZES IN GLOBAL SUPPLY CHAINS?
Pallet sizes differ between Asia and America, and repalletizing imported goods on arrival can add significant labour costs. RollerPlast developed a custom-sized pallet that nests the non-standard imported pallets, so products don’t need to be repalletized at all. The result is higher productivity and lower operating costs, and the client can now offer flexible, custom-sized manufacturing at a reasonable MOQ, which allowed them to bid on a sizable project in the Asian market.