Automotive Packaging Solutions
THAT REDUCE COSTS AND IMPROVE EFFICIENCY
ITB Packaging is an expert in the automotive packaging industry with nearly two decades of experience working with top OEMs, Tier 1, and Tier 2 suppliers of automotive parts. We specialize in packaging Interior trim injection-molded plastic parts. Our patented solution provides unparalleled part density in a corrugated box, bulk bin, or tote.
Trusted by Industry Leaders for Supply Chain Optimizing Packaging Solutions
As leading manufacturers and suppliers, our ISO 09001 Certified Quality Management System, our commitment to industry standards, and our ongoing improvement enable us to offer superior products and services. We adopt a comprehensive approach to examine all possible aspects of part protection and transportation.
Get Your Questions Answered
Contact us to learn how our automotive packaging solutions can increase space throughout the entire workflow.
Why ITB for Automotive Parts Packaging?
ITB Packaging manufactures custom, innovative expendable and returnable packaging solutions that combine dunnage and dividers into one collapsible unit. Our automotive packaging solutions deliver flat to save space and decrease costs throughout the entire supply chain. With our flexible paper and fabric materials, you can nest parts and increase density while maintaining your current dunnage size.
What Makes Our Packaging Unique?
1. A single SKU space-saving design that saves you warehouse and freight space, helping you lower costs.
Watch How ITB’s Solutions Work
2. An Innerleaf design that allows you to nest parts, which results in doubling your part density while maintaining the original pack size.
Innerleaf Design for Automotive Parts Packaging
Double-Part Density Case Study
The Challenge: An injection molding company was using traditional corrugated boxes with manually assembled partitions for T-20 bezels and side turns. They needed to enhance part density while maintaining the overall pack size.
The Solution: A collapsible single SKU design with pre-glued inserts, eliminating manual insertion.
The Results:
- Doubled pack density (from 30 to 60 parts per pack)
- Reduced cost per part by 30-65%
- Increased parts per pallet by 200-233%
- Streamlined packaging process and reduced labor requirements
ITB Solution A
ITB Solution B
3. Cost Savings Throughout the Automotive Supply Chain
- Increased Part Density: ITB’s innovative automotive packaging solutions, like innerleaf partitions, allow for more parts per pallet, reducing the number of shipments and lowering transportation costs.
- Lower Freight and Shipping Costs: With higher packing density and optimized space usage, fewer trucks are required, resulting in significant savings on freight and logistics.
- Reduced Labor Costs: Pre-assembled inserts and integrated dividers streamline the packaging process, cutting down on manual labor and reducing setup time.
- Minimized Material Waste: By eliminating die-cut processes and void fill, ITB reduces material usage, helping to lower overall packaging costs.
- Decreased Storage Costs: ITB’s space-saving solutions, such as collapsible cartons, reduce warehouse storage needs, freeing up space and cutting storage costs.
- Fewer Damaged Parts: ITB’s protective materials, like Nomar-coated paper, minimize damage during transit, reducing costs associated with returns, replacements, and insurance claims.
- Streamlined Inventory Management: Fewer SKUs and simplified packaging solutions help optimize inventory, lowering management and handling costs.
- Sustainability-Driven Savings: ITB’s recyclable and reusable packaging materials reduce the need for frequent replenishment, supporting long-term cost reductions.
Tier 1 Supplier Case Study
The Challenge: A Tier 1 supplier was shipping injection-molded interior trim parts that were prone to scuffing and difficult to nest due to their “L” shape. They packed 15 parts per tote, resulting in high packaging costs and inefficient use of floor space, leading to 2.5 truckloads per month.
The Solution: ITB Packaging introduced interleaf partitions with Nomar paper, allowing the supplier to fit 32 parts per pack. This change reduced the cost per part from $1.50 to $0.83 and cut their truckload shipments by 15 per year, saving $20,000.
The Results:
- Enabled customer to fit two parts per cell
- Increased parts per pack from 15 to 32
- Reduced cost per part from $1.50 to $0.83
- Reduced TL shipments by 15 per year, saving $20K
ITB’s Innerleaf Solution using Nomar paper
ITB’s Innerleaf solution using Nomar paper
4. Optimized for Automotive Returnable and Expendable Solutions
Returnable Automotive Packaging Solutions
Expendable Automotive Packaging Solutions
EXPENDABLE REUSABLE SOLUTIONS
Our expendable dividers are customizable paper-based solutions that can also be reused multiple times depending on the application.
Expendable Packaging Divider Samples
In-The-Box Elite Fabric
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Pop-N-Drop 20# Kraft
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Pop-N-Drop 20# Kraft Bin
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Smooth Kraft with Nomar Coating
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Smooth Kraft with Nomar Coating Innerleaf In The Box
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Smooth Kraft with Nomar Coating Divider
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ESD In The Box
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Nomar Pop-N-Drop For Automotive Parts
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Nomar Innerleaf In The Box For Automotive Parts
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Nomar In The Box For Roof Consoles
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Elite In The Box
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Tote Expendable Sized Pop-N-Drop
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20# In The Box With Automotive Parts
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Custom 20# Pop-N-Drop With Automotive Parts
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20# In The Box
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Elite Innerleaf
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20# Innerleaf Pop-N-Drop
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20# Innerleaf Pop-N-Drop With Injection Molded Part
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Nomar Innerleaf In The Box
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Nomar Innerleaf In The Box
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Nomar Innerleaf In The Box
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| ITB Expendable Materials providing class A protection | Replaces |
|---|---|
| Smooth Kraft: Durable material with strong protection levels for lightweight items. Ideal protection for molded plastic parts and majority of painted plastic parts. 100% recyclable material | Corrugated and chipboard partitions |
| Nomar Coated 20# Kraft Paper: We add Nomar coating to our 20# Kraft Smooth Kraft Paper to provide additional surface protection for the most sensitive surfaces including Piano Black and High Gloss finishes. | Corrugated with Nomar; PE coated corrugated |
| ESD Paper: ESD (Electrostatic Discharge) provides additional static dissipating properties that are inherent to the natural static dissipating properties of paper. | ESD chipboard or ESD corrugated |
| Elite Fabric: Spun bound polypropylene which provides special protection for highly sensitive class "A" parts and is recyclable. | Bagging of parts |
RETURNABLE SOLUTIONS
Our returnable solutions are customizable fabric-based solutions that retain the benefits of die-cut and sewn products while solving problems such as materials that wear easily or pull away from the Pcorr, causing part and cell damage.
Returnable Packaging Divider Samples
LX High Density Cells
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Blue Plush in Tote Close Up
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Blue Plush in Tote
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LX Fabric nesting
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Blue Plush Varied Cells
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Bulk Bin Interleaf Cells
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Blue Plush Nesting
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LX Fabric
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LX Tote With Dust Cover
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Returnable Tote With Dust Cover
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LX Returnable Totes
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Returnable Tote With Automotive Parts
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LX Innerleaf
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Custom LX Divider
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LX Divider in a Pcorr Tote
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LX Collapsible Centersplit
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Evolon
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Blue Plush Collapsible Centersplit
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Blue Plush Centersplit With Automotive Parts
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Blue Plush Centersplit
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| ITB Returnable Materials providing class A protection | Replaces |
|---|---|
| Blue Plush: Blue-brushed polyester on both sides with polyester center for additional loft and durability. Provides excellent part and surface protection for a wide variety of molded parts. | Pcor (plastic corrugated) Spunbond; Pcor Brushed Polyester; Pcor Soft Edge; Sewn Headliner; Soft Edge |
| LX: This is a gray Spunbond Polypropylene felt style product. Entry level returnable fabric material. | All Spunbond PP; Spunbond PP on Corrugated Plastic; Spunbond PP on Chip Board |
| Evolon: a compact fiber structure that is both strong and exceptionally soft. This proprietary threadless fabric eliminates the interaction between your sensitive products and beading of threads in comparison to sewn technology. Provides static dissipating properties. | Microfiber; Pcor (plastic corrugated) Spunbond; Pcor Brushed Polyester; Pcor Soft Edge; Sewn Headliner; Soft Edge |
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5. Products Designed for both Expendable and Returnable Automotive Packaging
- In-The-Box dividers come pre-assembled inside corrugated boxes
- Pop-N-Drop dividers easily pop open and drop into your expendable or returnable boxes, totes, and bulk bin containers
6. Comprehensive Supply Chain Benefits
Our packaging solutions do not require die-cut tooling like other manufacturers. This means more efficient and productive processes that help us provide faster turnaround for our customers. Our lean processes use far less labor and provide customer savings of about 60% less than sewn and 20% less than comparable fabric covered PCORR.
Our products use 30% less material in our processes compared to typical dividers. This helps to create a smaller environmental footprint and lower manufacturing costs, which we pass on to our customers.
Our flexible cells protect products better during transport, and our materials are glued from top to bottom, providing greater strength and durability for longer lasting products, and last longer and yield lower costs compared to fabric on Pcorr or fabric on foam.
All Expendable products collapse and lay flat which create significant advantages including: a decreased need for plant storage space by as much as 25-75%, lower shipping expenses with more boxes and dividers per skid, and better warehouse efficiency with fewer high-low and line-side moves.
Returnable bins and dividers can collapse to create plant storage space savings and lower return-shipping expenses by nearly three-fold, because in many cases ITB bulk bins dividers can be collapsed inside the bin when empty. For example, 78 full 4845-34 bin containers fit on a full-size truck and 208 collapsed bins fin in the same truck.
Our expendable dividers are more efficient, safe, about 50% lighter weight and use more operator-friendly materials that require less handling. This makes our products much easier and faster to assemble and/or insert into containers. Our returnable solutions use more operator-friendly material and require less handling, making them much easier and faster to assemble and insert into containers. In fact, by using screws on one side for security and hook/loops on the opposite side, you can set up and knock down dividers in bins in just 30 seconds each way.
Our custom-sized cells increase box densities by an average of 12 to 18% compared to die cut systems and up to 100% when Interleaf systems are used. Interleaf nesting allows uniquely shaped products to fit together in tight units, and by avoiding air cells, you can use the entire interior of the container and increase shipping and work efficiencies at the same time. To view product density comparisons, see the Expendable Samples section above.
Our custom-shaped cells increase densities by an average of 20% compared to die cut systems and up to 100% when interleaf systems are used. Interleaf nesting allows different shaped products to fit together in tight units, and by avoiding air cells, you can use the entire interior of the container and increase shipping and work efficiencies at the same time.
Our expendable and returnable automotive packaging dividers provide Class A protection and repeatedly outperform corrugated in tests. Soft materials and non-friction paper surfaces that are flexible and engineered to custom-fit products work together to provide superior protection with less abrasion than hard-wall dividers .
Our returnable product materials, such as Soft Blue Plush, Evolon, and LX materials, are flexible and engineered to custom-fit products and provide superior protection with less abrasion than hard-wall die-cut dividers, without compromising strength. In contrast, Die-cut systems cause parts to rub against the walls causing quick fabric wear, exposure to glue and Pcorr, and extra movement in transit. Because our material flexes with the part, it eliminates the pressure points that cause part damage.
Objections, Misconceptions and ITB Packaging Solutions
- Product Protection: Our solutions, whether expendable or returnable, are designed to absorb shock and vibration rather than transfer it to the parts they protect. This is critical for keeping parts safe during transit. Additionally, our packaging is trusted by all major OEMs, proving its reliability and effectiveness.
- Stacking Strength: While this concern has some merit, it’s typically not a significant issue for injection-molded parts because they are relatively lightweight. In most cases, the light weight of the parts makes stacking strength a non-issue.
- Materials Used: We offer a variety of paper grades, surface coatings, and returnable fabrics to meet the specific needs of your parts. Whether it’s weight-bearing capacity or surface protection, we have solutions tailored to address both.
- Non-sewn Bottoms: For customers concerned about non-sewn bottoms, we offer additional solutions like foam bottoms or cut sheets to provide the extra protection and durability required.
Partnering with ITB has streamlined our packaging process, delivering measurable gains in cost savings, floorspace efficiency, and customer satisfaction. The increased pack density and reduced freight damage have been game-changers for our operations.
—TYLER JOHNSON, PRESIDENT, SUPERIOR TRIM
Why Choose ITB Packaging?
If you are looking for a high quality packaging solution for the automotive industry, consider ITB Packaging. Our expendable and returnable solutions provide optimal protection, greater productivity and efficiency, and can help you meet your sustainability goals. Download our Automotive brief and information sheet to learn more about working with ITB Packaging.
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Discover how our automotive packaging solutions can serve your operational needs and support long-term business objectives.
Request a Quote
Ready to revolutionize your packaging? Take the next step toward a more cost-effective, space-saving, and sustainable future today.
AUTOMOTIVE PACKAGING VIDEOS
Learn how to use our returnable or expendable automotive packaging solutions
Glossary of Terms
Typically, automotive packaging solutions are designed to be either disposed of after one use (expendable packaging solutions) or reused multiple times (returnable packaging solutions). However, ITB Packaging’s expendable packaging can often be reused multiple times, depending on the application. Learn more about the differences and how to choose between “Expendable vs. Returnable Packaging.”
Pop-N-Drop dividers are a unique product offered by ITB Packaging designed to simplify the process of packing and unpacking in automotive logistics. These dividers “pop open” and “drop” into place, reducing assembly time and improving warehouse and transport efficiency.
In-The-Box dividers are ITB’s intuitive, all-in-one box and divider solution that comes fully assembled. This single SKU solution is completely collapsible, ships flat, and stacks just like empty corrugated boxes, saving space, increasing pack density, and enhancing packing processes.
Traditional methods used in packaging include die-cutting, which involves cutting shapes from materials using a die, and sewn technologies, which involve stitching materials together. These processes can be labor-intensive and less environmentally friendly compared to newer solutions offered by ITB Packaging.
Containers used in industrial and commercial environments for storing and transporting large quantities of goods. ITB Packaging provides solutions to enhance the usability of these containers with custom-fit dividers for efficient space utilization.
A methodology that focuses on minimizing waste within manufacturing systems while simultaneously maximizing productivity.
Also called carbon footprint is a company or product’s impact on the environment, including the use of resources and the generation of waste.
Refers to the design of products that optimize human well-being and overall system performance.
A measure of how efficiently space is utilized within a box. Higher box density means more products can be packed securely without wasting space.
A packing technique where items are stacked in a layered pattern that maximizes space utilization and minimizes movement. This technique is particularly useful for protecting delicate parts during transport.
The compact arrangement of parts within a packaging system, which helps in maximizing space and minimizing damage during transportation.
The highest level of protection offered in packaging, ensuring that the most delicate and high-value items are safeguarded from any potential damage during transit.
