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1 ⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪
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2 ⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪
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⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪
⨪⨪⨪⨪⨪

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⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪
⨪⨪⨪⨪

⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪
⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪e existing fibre board boxes etc to come to you
for analysis.
I have summarised the requirements and key information including from previous
correspondance below.

PLASTIC PREFORM BINS

Requirement is to provide a PP fluted alternative to exsiting fibreboard

solution with as good or better top load, side wall strength and of course,
life span.

Specifications

Preform Bin Sleeves

Exising fibre board Bin Sleeves:

 “Octo-Bin” (8-sided) style construction formed by single sheet of

heavy duty tri-layer fibre board that is stapled together to form a ring
after other processes are done
 Machine pressed to compress the flute in the creases to allow the sheet
to fold into the 8-sided shape
 Flutes running vertically
 Die-cuts for handle holes
 Printed 1C black with protective lacqure layer
 Stacking 4 high

Proposed New Preform Bin Sleeves in fluted PP:

  Design:

(1) Equivalent or better than existing fibre board solution

(2) Subject to your advice, we expect that the overall design will
be similar in PP to that of fibre board including the Octo-Bin
shape -- which provides the squared off corners to increase top
load performance – will be necessary even in PP to keep the top
load and overall side strength. However, if PP sheet can reach
the top loads with out these squared corners then perhaps the
sleeve and bin shape can be 4-side square. Please consider.

(3) All edges to be sealed against ingress

(4) Weight of product in box is typically 400kg but expected to

become 600kg

(5) Stacking minimum 4 bins high preferably 6 bins high

 PP Recipe  as per the exisiting layer pad recipe or as per your advice

 Colours  options for quoting in order of likelihood:

(1) Light grey (off white) -- not mid or dark grey

(2) Light silver metallic

 Printing  1 colour black with protective clear coat layer / artwork to

be revised

Preform Bin End Caps (Top & Bottom / 2 per Bin)

Exising fibre board solution for Preform Bin End Caps:

  Fibre board sheet in high quality board like 1C Super
 Die-cut
⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪
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⨪⨪⨪
 ⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪
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⨪

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3 ⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪⨪
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⨪⨪⨪⨪⨪ersion from but can do this subject to your inputs. Perhaps there
is a solution that you already have or can easily engineer using your
ImpraBoard or otherwise.

Specifications
Existing Timber Top Boards for Bottle Pallets

 Picture frame type device made from timber boards ~100mm wide
 Sized to AU pallet at 1165*1165
 Approx 20mm thick
 PP fluted sheet stapled to the underside -- which acts as the final
layer pad for the open neck of the bottle – and allows the board to be
lifted by vacuum pads in de-palletiser machine

Problems with this board include:

 Uneven pressure on the bottles due to the picture frame style vs a full
flat sheeet style of design – outside rows of bottles get high compressive
forces when top loaded with another palelt on top and also when strapped
due to the flexing of the frame
 Longevity of the frames
 Timber contamination

Proposed New Plastic Top Boards for Bottle Pallets

 Proposed design:

(1) Single piece or 2 piece construction

(2) Size = 1165 * 1165 by approximately 20mm thick

(3) Flat surface on the underside

(4) Good rigidity / no warping

(5) Formed sections on the top sides to support locations of straps

 (6) Long lasting

(7) Sealed against ingress

(8) Easy to clean

(9) High top load performance and impact strength

 Method of manufacture is open for discussion however options might

include:

(1) Injection moulded top side with simple flat sheet (solid most
likely over fluted) – welded together to form sealed board – top
side with series of cross ribs for support and rigidity

(2) Fluted PP super heavy duty with all edges sealed and heat formed
sections or inserts for strap points

(3) Blow moulded

 Recipe  PP or HDPE

 Colours  options for quoting in order of likelihood:

(1) Violet (Purple 1C) – specific matched corporate colour unless

stock colour is close

(2) Orange – as per existing layer pad

(3) Dark silver metallic

 Printing  1 colour black (or white) with protective clear coat layer /
artwork to be revised
Quantities for Quoting

We currently have around ~5000 in our fleet and this is projected to double.

Obviously we will produce sufficient quantities to fill a full container –

either a 20’ or 40’. Initially volumes would be higher to replace the fibre
fleet and then would be more maintenance volumes so need to plan for mixed lot
containers where sleeves and end caps might come together – or with other
things like layer pads.

However, for now, please quote in production lots of 1000, 2000, 5000, 10000.

Advise the estimated quantities of each that will fit in a 20FCC or 40FCC.

GENERAL COMMENTS & QUESTIONS

5 Anti-static. If anti-static additive lasts in the polymer and is

effective over a long period of time then please advise – if so we will
add it to the recipe. Otherwise if it is useful for a while and then fades
away then no point.

6 Bi-colour extrusion for Impraboard sheets? Does Impact have the ability
to run 2 colours on the extruder to have an inside colour and then an
outside colour just for the outside skin? I like the idea of using
metallic colours but the cost is normally higher – so if you have this
capability then perhaps the cost will not be so different if we can put the
metallic colours on just the outside skin and a standard light or dark grey
on the inside layer and flutes.
 7 RFID. For asset management, we have considered the idea of
incorporating an RFID label or chip into the Preform Bin Sleeves and the
Pallet Top Boards to keep track of these. Potentially also the other
sheeted product like the Preform Bin End Caps and also the standard Layer
Pads by way of a self adhesive sticker. If you have experience with this
please advise.

8 Plastic Pallets. If you have capability with injection moulding of

plastic pallets then please advise. We have a proposed pallet design that
we are looking to mould.

Di infokan material untuk trial beban untuk box oktagonal belum tersedia

Sesuai convo dengan Bu Ika 14/05/2020 akan di buatkan material dg spec IB T6

grey Gsm 1500

Wellman Packaging

Ini ada request yang cukup mendetil dari WELLMAN yang biasa ambil LayerPad
kita.

Basically ada 2 items yang diminta:

1. Preform Bin, yang terdiri dari

a. 1pc Sleeve (Selongsong) fully sealed, berbentuk octagonal atau

bentuk lain yang bisa perform untuk berat stacking 3.6MT

b. 2pcs End Cap (Tutup Atas & Bawah) fully sealed, locking system

2. Top Boards (Tutup Atas Pallet) fully sealed, dan harus bisa mendistibusikan
berat secara merata ke botol kosong di bawahnya.

Dan ada 4 pertanyaan general:

1. Maksimal lifetime antistatic kita

2. Kapabilitas Bi-color extrusion di KD

3. Penggunaan RFID pada Preform Bin

4. Kapabilitas injection moulding plastic pallets di KD

Mohon dipelajari dulu lalu nanti kita bisa compare notes ya.