Zero breakages goal

The Smartstak system addresses the issue of pallet instability in transporting glass bottles

The traditional method of transporting glass relies on flat extruded plastic pads, wooden top frames, banding and plastic bags, securing loads to a maximum of ten layers, and not making significant moves towards zero breakages.

Loadhog recognised that its Lid product was not the complete answer and was convinced a step-change product could be developed to minimise breakages. Three of the UK's largest glass bottle manufacturers worked with Loadhog to develop the Smartstak system.

Industry statistics show 1% of all tall stacks collapse, or are compromised during transit, and never reach their destination, with the estimated cost to the industry exceeding ?2.5m.

Loadhog's technical challenges were to prevent bottles 'migrating' outwards during transit, and strapping losing tension. The company worked with some of the industry's major players, universities and tooling partners to bring the Smartstak to market.

Smartstak required an investment of ?500,000 in tooling.

During the design process Loadhog tested assumptions and minimised risk, utilising the Pira test laboratories to simulate transportation movements.

The system comprises two elements. The Smartpad is a plastic injection moulded layer pad with a unique waved edge.

It was developed to solve the stability issue, differing from the profile of a conventional pad. Its edge not only provides the glass block with stability but also encourages bottles to 'migrate' to the centre of the pad rather than to the edges, eliminates bottle scuffing and acts as a barrier when a pallet is subjected to impact forces. More than 500,000 pads are currently on rental, moving in excess of eight million bottles weekly.

The two-piece injection moulded Smartframe solves the problem of strap tensioning, housing springs to provide 1,000kg stored energy, to compensate for the elastic properties of plastic banding, and acting as a damper to ensure even tension and load distribution throughout the life of the pack.

As fewer straps are required, the time needed to build a pallet of glass is reduced by up to 20 per cent. Resulting from its inherent strength, customers can confidently increase the number of layers from ten to 11, reducing vehicle movements by ten per cent. Savings in packaging are also generated by reducing strapping and eliminating the need for shrouds which have traditionally been disposed of in landfill.

A pool management system has been written and developed, providing accurate data on pads' and frames' location, thus minimising working capital in the supply chain and providing a 24-hour replenishment service.

Smartstak has not only set new standards in glass transportation, but also made a significant environmental contribution.Manufacture of the Smartpad utilises recycled polypropylene in a factory which is 'best in class' for environmental efficiency. Any product returned as damaged is reground and utilised in the manufacture of new product.

This year, Smartstak has made significant progress. The system is now being used by the most innovative glass bottle manufacturers, major brewers and soft drink manufacturers.

Loadhog is confident that Smartstak will be adopted progressively as the industry standard in the UK and Europe and the company is already talking to other manufacturers to license the technology in other parts of the world.

Smartstak demonstrates that innovation can be achieved in mature industries. The product could help the glass bottling industry reach its holy grail of zero transportation breakages.

Australian breakthrough Loadhog has opened up the Australian market by securing almost £2m in sales to a leading global packaging manufacturer, after investing almost £500,000 in bespoke moulding tools.

Under an initial £1m deal the new tools will produce 40 per cent larger Smartpads and Smartframes for Amcor, one of Australia's largest glass manufacturers.

After pilot testing Smartstak, Amcor has specified the system as the standard method of transporting containers for its Australian and New Zealand operations.

Smartstak operations manager, Dave Arthur, says: "These sales are a major coup for Loadhog and well worth our investment. What is especially pleasing is that this customer sees Smartstak as the standard for transporting glass bottles, which is a major step towards establishing the system as the industry standard, not just for Amcor.We are currently talking to a number of other major bottle manufacturers an

Australian breakthrough Loadhog has opened up the Australian market by securing almost £2m in sales to a leading global packaging manufacturer, after investing almost £500,000 in bespoke moulding tools. Under an initial £1m deal the new tools will produce 40 per cent larger Smartpads and Smartframes for Amcor, one of Australia's largest glass manufacturers. After pilot testing Smartstak, Amcor has specified the system as the standard method of transporting containers for its Australian and New Zealand operations. Smartstak operations manager, Dave Arthur, says: "These sales are a major coup for Loadhog and well worth our investment. What is especially pleasing is that this customer sees Smartstak as the standard for transporting glass bottles, which is a major step towards establishing the system as the industry standard, not just for Amcor.We are currently talking to a number of other major bottle manufacturers an