Harrison EstesMay 17, 2016Visit to Cartagena, Colombia

While visiting Ajovers manufacturing plants in Cartagena, Colombia, I was able to observe various manufacturing processes of different types of packaging. Some of the manufacturing processes were similar if not the same as what I have studied in school. There were several plants that I toured which ranged from the production of polystyrene to the injection molding of disposable cutlery. Seeing the production of the hinged containers, PVC and PC roofing tiles, disposable cutlery, and the pots/tanks was all very new to me. While at Clemson, I have had several packaging science labs in which we observed the operation of blown and cast film machines where films were produced. I feel that my observations of Ajovers packaging plants were extremely beneficial to me from a packaging standpoint because I now have a better understanding of all that goes into the production of packages and the importance of efficiency. My visit to Ajover also entailed the shadowing of Lila Sepulveda and Andys Bohorquez in which we observed the corrugate packaging of many of Ajovers products. Lila, Andys and I spent a majority of the days visiting the warehouses to check the efficiency of the corrugate boxes to make sure that they were appropriately sized for the products that were packaged. If there was excess space in the boxes, we determined how much material could be removed to ensure more efficient packaging from both a protection and cost savings standpoint. The re-dimensioning of the boxes does not only save the company money from a box cost standpoint but as well as shipping and transport. With smaller dimensioned boxes, the cube cases of the packaged products also changed allowing more cases to be placed onto pallets which in turn results in higher volume of products shipped. With changing the dimensions of the boxes, the amount of boxes that are able to be loose loaded onto a container also increased. With eliminating excess space from boxes by decreasing box size, we were able to generate savings for the company from both a material and transport perspective. After the collection of re-dimensioned box data, we created an excel spreadsheet with the current box specifications which included box dimensions, box material, palletized and loose load cube cases, cost of both individual boxes, and monthly consumption of specific boxes. The newly dimensioned boxes and the cube cases that were generated from CAPE were then used to determine the savings that would result with redesign of oversized boxes. We also used data collected from PeopleSoft to determine if the thickness of the corrugate was appropriate for the weight of the products. After all information regarding current box designs and proposed designs were input into the excel document, it was easier to compare the difference between the two.While in Cartagena, we also worked on the redesigning of the Darnel Stretch Wrap dispenser, which was having issues with tearing of the corrugate material. The dispenser that we observed when I arrived had a few flaws in regard to placement of cut outs which resulted in damage to the box after extended use. We brainstormed several ideas in order to reconfigure the box to create a more sustainable and easy to use package. After changing the placement of the finger hole cut outs, the film dispensing cut out, and the size of the tuck flaps on the top of the package, we were able to request a sample from the supplier. After receiving the first sample, we were still unsatisfied with the construction of the box so we made a few more changes to the sizing and placement of cut outs and requested another sample. After observing the second sample, we were happy with the effectiveness and integrity of the newly designed box and requested approval for the new design. Overall, I found that my trip to Cartagena was extremely beneficial to me as a Packaging Science student and believe that the work Lila, Andys and I conducted will in turn not only save the company money but also increase company efficiency and customer satisfaction in regard to the newly designed film dispenser.

In summary, the tasks of my visit included: The redesign of Darnels film dispenser for stretch wrap Redesigning of many darnel products corrugated shipping boxes Changing of corrugated material based on net weight of packaged product Create cube case reports using CAPE and Truck Fill to understand how redesigning of box dimensions would affect palletization as well as loose load of newly dimensioned boxes Touring of all Darnel plants in Cartagena Film plant (PVC stretch wrap and shrink film) Roofing tiles plant (PVC and polycarbonate roofing tiles) Cups Plant (EPS foam cups) Injection Plant (PS disposable cutlery) Foaming Plant (EPS disposables -trays, plates, hinged containers-) Thermoforming Plant (PET disposables -domes, hinged containers-) Straw plant (PE straws and stirrers) Sheet plant (bathroom walls) Pots/Tanks plant (PE flower pots and water tanks) Extrusa (polyolefin films - micro perforated and others-) Roofing tiles (second plant produces two types of roofing tiles; 5 layer and 3 layer; they layers include galvanized steel, asphalt, and aluminum. 5 layer roofing tiles consists of steel-asphalt-aluminum-asphalt-aluminum. 3 layer is steel-asphalt-aluminum) Discussed options for different product configurations for packages that were unappealing to customers (created a nesting pattern which not only created a more appealing configuration but also decreased dimensions of the corrugate box) Photos of boxes in need of re-dimensioning and the redesign of Darnel Film Dispenser are included below

Darnels Current Stretch Film Dispenser

With the current film dispenser design, there were many issues pertaining to the placement of the cutouts. The two finger hole cut outs were positioned too close to the edge of the box creating an issue with the corrugate tearing. The finger hole cut outs were also a little large in size so we decided to decrease the diameter of the circles. Another change that we made was to make the tuck flaps on the top of the box smaller and further away from the finger hole cut outs to avoid tearing of corrugate. The final change that we proposed was to decrease the length of the dispensing cut out as well as round the edges of the cut out. Rounding the edges of the cut out decreased the distance from the edge, which in turn decreases the risk of box tearing.

Redesign of Stretch Film Dispenser

With the redesign of Darnels Stretch Film Dispenser, the length of the tuck flaps on the top of the box were decreased to increase the distance between the finger and dispensing cut outs. By increasing the distance between the cutouts and the edge of the box, the likelihood of the corrugate tearing is reduced. These small changes can make a word of difference as far as the sustainability of the box. The finger hole cutouts as well as the dispenser cut out were re-dimensioned and still provide appropriate dispensing. Circled regions show the increased distance between box elements that contributed to corrugate tearing.Measuring of Current Boxes

Lila, Andys, and I spent two weeks checking boxed products to determine if the dimensions could be decreased while still protecting the product which in turn would save the company money on both box cost as well as shipping. We also determined that we could decrease the ECT on several boxes due to the weight of the packaged product. Over the course of the two weeks, we checked over 60 boxes and were able to propose redesigns for the majority of them. Current box design

This is an example of one of the boxes that we proposed to redesign. After taking measurements from the current box and determining new box dimensions, we requested samples from the box supplier. After receiving samples, we tested to see if the newly designed boxes would appropriately contain the product. Several of the samples needed to have material added to the length, width, or height. However, even with adding material to the boxes, the redesign would still be a better alternative to the company as far as cost.

Redesign of box

CAPE ReportsTo conclude my visit to Ajover in Cartagena, Lila and I spent a great deal of time using CAPE to have a better understanding of how the proposed box designs would affect the palletized and loose load of the packaged products. After creating cube cases for all re-dimensioned boxes, we determined that decreasing the box dimensions would not only save the company money from a box standpoint but also from a shipping standpoint. We found that the palletized and loose load cube cases for mostly all the redesigned boxes increased. These increases allow for more packaged product to be transported resulting in company savings.