Request an overview to see how higher part density can reduce shipments, handling, storage, and costs for your company.
Higher part density means fewer shipments, fewer pallets, and lower total cost across freight, handling, storage, and packaging.
ITB packaging solutions are engineered around your parts to maximize density without sacrificing protection—especially for Class A and high-finish injection molded parts.
Density drives savings across your whole supply chain.
What Would Higher Density Do for You?
Why Density Matters
When you increase part density per pack, you reduce:
- Truckloads and freight spend
- Warehouse labor and material handling
- Storage footprint and floor space
- Packaging material usage
- Carbon emissions
Our customers see measurable improvements across all five areas.
See the Impact on Freight Costs
Proven Freight Impact
- Up to 30% higher part density
- 23% fewer shipments
- Up to 50% reduction in truckloads with Innerleaf designs
- Fully collapsible packs improve backhaul efficiency
Fewer trucks on the road means lower freight costs and a smaller environmental footprint.
Handling & Labor Savings
Warehouse labor costs have increased significantly in recent years.
By increasing parts per pack and reducing pallet count, teams spend less time:
- Moving material
- Staging pallets
- Managing overflow storage
Fewer pallets = less labor required.
Storage Footprint Reduction
Storage rates continue to rise.
ITB designs help reduce warehouse space by:
- Using collapsible packs
- Eliminating multiple SKUs for boxes, dividers, and chipboard
- Improving container utilization
Everything is designed to work together as one system.
Designed for Challenging Parts
Our solutions are ideal for lightweight injection molded trim parts, including:
- Class A surfaces
- Piano black finishes
- Complex geometries
- L-shaped and asymmetrical parts
Design Advantages
- Flexibility: Partitions adapt to part geometry for tighter nesting
- Innerleaf: Additional material layers increase density for difficult parts
- Edge-to-Edge: Uses the full container footprint—no wasted air space
- Custom Fit: Packs designed around each part to maximize density per box, pallet, and truck
Proven Results from Real Programs
Real-World Results
- Tier 1 Automotive SupplierChallenge:
- Sensitive A-side surfaces
- Poor nesting with traditional partitions
- High packaging cost per part
Solution:
- Innerleaf partitions with protective paper
- Adjusted pack footprint to increase cell count
Results:
- Increased parts per cell
- Cost per part reduced from $1.50 to $0.83
- Fewer truckload shipments per year
- Reduced floor space
Sustainability Through Density
Every mile driven by a semi produces approximately 3.5 lbs of CO₂.
By reducing shipments, ITB solutions help:
- Cut transportation emissions
- Lower material usage
- Reduce waste
Some ITB divider designs use up to 66% less paper than traditional corrugated dividers.
Built for Speed & Flexibility
- In-house design and manufacturing
- No tooling or dies required
- No minimum order quantities
- Fast quotes, designs, and samples
Our team works directly with your parts to develop the right solution quickly, shipping throughout North America.
Ready to Increase Density?
If you’re shipping injection molded automotive parts and looking to reduce freight, labor, and packaging costs, we can help.
Talk to our packaging team today.