CASE STUDY No. 9604

KEY WORDS= PARTITIONS--BOTTLE SHIPPING CASES

Jefferson Smurfit Corporation
1401 W. Ellerman
Litchfield, IL 62056

Contact: Greg Lawrence, General Manager, Litchfield Operations. Tel: 217-324-6591.

Summary

By replacing a five-piece case partition with a lighter weight, one-piece unit, the company has reduced material usage about 20% while increasing stacking strength.

Action

Jefferson Smurfit Corporation (JSC) is the third largest U.S. manufacturer of chipboard partitions, used to compartmentalize cardboard cartons of bottled goods. JSC also makes the largest multicell partition--one with 36 or more cells, mostly used for pharmaceuticals, cosmetics, and other small items. However, JSC was the smallest producer of the commodity partition--the 6-, 12- and 24-cell partitions used extensively in the food and beverage industry.

To become more competitive in the commodity partition market, JSC decided to produce a new 12-cell partition. After 5 years of development, the company introduced its new "Q Stack" partition. The glued, one-piece unit is manufactured of .037 chipboard, made of 100% recycled content. The new 12-cell partition replaces a slotted five-piece partition manufactured of .047 chipboard rollstock that was 20% heavier.

Although the new, one-piece unit is lighter in weight, it is stronger than the old partition. This is due primarily to the fact that it is a solid piece. Tests show that the .037 Q Stack partition has greater stacking strength than 175# test, B-flute corrugated cardboard commonly used to manufacture slotted partitions, and is comparable in strength to 150#, C-flute corrugated. Users also note that the old, slotted partition could shift and fall out of the shipping case, interrupting operations.

Q Stack is produced in six calipers from .028 to .040, in cell sizes from 1-3/4 to 4 inches, and heights from 5 to 15 inches. JSC lists the user benefits as follows:

  1. Increased stacking strength
  2. Improved load-bearing strength
  3. Better sturdiness
  4. Easier to insert into the corrugated shipping case
  5. Reduced case, partition, and product damage
  6. Reduced package weight

JSC says it has benefited from the new partition by:

  1. Reducing material requirements by 20%
  2. Reducing storage requirements
  3. Reducing production costs by 10%
  4. Reducing production scrap rate

Payback

JSC made a significant investment in R&D to perfect the Q Stack and bring it to market. The company expects to recover its development costs over time with increased sales of the innovative new partition. "There has never been anything like this available before," a JSC representative said. "This allows cost savings for our customers." Thus far the largest users have been glass bottle manufacturers.

 

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