Redesigned blister brings benefits throughout supply chain | Packaging World Case Study

“Through a packaging redesign and reducing depth of draw on a PVC thermoform, Energizer Holdings generated operating efficiencies and cost savings galore while racking up some...

“Through a packaging redesign and reducing depth of draw on a PVC thermoform, Energizer Holdings generated operating efficiencies and cost savings galore while racking up some serious sustainability points.”

Packaging professionals have proven time and time again that a redesign can mean massive improvements in efficiencies and overall savings for supply chains. This case study, written by Packaging World VP Editor, Pat Reynolds, showcases the impact that revisiting the packaging of razors had on the supply chain of Energizer Holdings.

Energizer Holdings tasked our packaging team with a redesign for their eight-pack of men’s private-label razors. By removing the excess air in the packaging, we were able to not only decrease packaging costs, but significant savings were realized throughout the entire supply chain, with an added bonus of sustainability.

Key outcomes of the packaging redesign include:

  • Increased pallet density by 86% (from 21 to 39 cases)
  • An improved overall shipping density per cubic foot by 61%, resulting in a more favorable LTL freight classification.
  • A savings of  2,515 gal of diesel and 56,333 lb of CO2 emissions
  • A savings of more than $200,000 on expenses directly related to eight-count primary packaging in the first year.

Read the entire case study on Packaging World’s website.

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