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Retail Innovation– Final Report

Reusable ‘Carrierpac’ packaging for kitchen worktops at B&Q

Results from a trial with B&Q demonstrating the technical ability of the “Carrierpac” - a multi-trip plastic package - designed for efficient transportation of kitchen worktops to customers and to minimise levels of product damage.

Project code: RSI001029 ISBN: 1-84405-345-8 Research date: December 2006 Date: October 2007

Front cover photograph: Use of reusable Carrierpac for delivery of kitchen breakfast bar at B&Q

Waste and Resources Action Programme (WRAP), B&Q and Outpace Ltd believe the content of this report to be correct as at the date of writing. However, factors such as prices, levels of recycled content and regulatory requirements are subject to change and users of the report should check with their suppliers to confirm the current situation. In addition, care should be taken in using any of the cost information provided as it is based upon numerous project-specific assumptions (such as scale, location, tender context, etc.). The report does not claim to be exhaustive, nor does it claim to cover all relevant products and specifications available on the market. While steps have been taken to ensure accuracy, WRAP cannot accept responsibility or be held liable to any person for any loss or damage arising out of or in connection with this information being inaccurate, incomplete or misleading. It is the responsibility of the potential user of a material or product to consult with the supplier or manufacturer and ascertain whether a particular product will satisfy their specific requirements. The listing or featuring of a particular product or company does not constitute an endorsement by WRAP and WRAP cannot guarantee the performance of individual products or materials. For more detail, please refer to WRAP's Terms & Conditions on its web site: www.wrap.org.uk.

Published by Waste & Resources The Old Academy Tel: 01295 819 900 Helpline freephone Action Programme 21 Horse Fair Fax: 01295 819 911 0808 100 2040 Banbury, Oxon E-mail: [email protected] OX16 0AH

http://www.wrap.org.uk/

Executive summary Kitchen worktops are an essential part of any kitchen sold by B&Q. Significant levels of packaging are required for B&Q to successfully deliver any worktop from its range to a customer’s home. This packaging provides protection to prevent transit damage to the corners, edges and presentation surface of the worktop. Even the smallest dent, scrape or scratch is likely to mean the worktop will be rejected by the customer. This increases costs (wasted cost of manufacturing and shipping the damaged product, the cost of its disposal), increases waste and decreases customer satisfaction. B&Q currently delivers thousands of kitchen worktops per week, resulting in approximately 1,100 tonnes of packaging ending up in the household waste stream per year. At a retail price of between £27 and £830 per kitchen worktop, minimising product damage is essential to avoid the wasted cost of production, distribution and disposing of damaged and unsaleable stock. The current transit packaging for a B&Q kitchen worktop is designed to protect it for just a single journey from the B&Q Showroom Fulfilment Centre to the customer’s home. The single-trip packaging consists of an individually printed, large die cut corrugated board wrap. The worktop is shrink-wrapped in plastic film and placed inside the carton; the carton is folded around the worktop and plastic tape applied. An information leaflet is taped to the outside of the carton to identify the product inside the pack. The current process adds packing time and costs at the Showroom Fulfilment Centre, where home delivery orders are prepared, as well as additional bulky packaging for the customer to dispose of which is unlikely to fit into typical household recycling or general waste bins. Packaging consultants Outpace worked with B&Q to develop a multi-trip plastic package called Carrierpac. Carrierpac is manufactured from plastic materials with approximately 45% recycled content and is recyclable at the end of its life. Its robustness has been tested during a trial to ensure it protects the product from damage during delivery to the customer. The initial phase of the trial involved 300 Carrierpacs designed to carry 3 m long by 60 cm wide worktops. This was followed with a second phase involving 100 Carrierpacs designed to carry 3.6 m long by 60 cm wide worktops and 100 Carrierpacs designed to carry a 2 m long by 90 cm wide breakfast bar worktop. These specifications were chosen to ensure the longest, heaviest, widest and commonest types of B&Q kitchen worktops were included in the trial.

Figure 1: Current single-trip packaging for worktops

Figure 2: The reusable Carrierpac

Within the trial period, the highest recorded number of uses of a single Carrierpac was 18 trips. No damage to worktops was reported and no customer complaints were received. The trial demonstrated the technical ability of the Carrierpac to get worktops to customers efficiently with reduced levels of damage. In addition, the Carrierpac provides a more professional presentation of the product to the customer, while unpacking the worktop at the point of delivery allows any immediate issues to be resolved

Reusable Carrierpac for kitchen worktops at B&Q 3

(e.g. wrong worktop, obvious damage). This enables the product to be returned straightaway, allowing a faster response to failed deliveries. Overall, the time required to use the Carrierpac system made it similar to the single-trip system, as the shorter time taken to pack a worktop into a Carrierpac was balanced by the time taken to log, inspect and prepare the Carrierpac ready for its next trip. Carrierpacs were found to withstand periods outside on customer’s driveways, paths, etc. with no detrimental effect, unlike the cardboard single-trip packaging which would absorb moisture and eventually disintegrate. The trial proved that Carrierpacs not only resisted handling damage but, because no sharp objects are needed to open the Carrierpac, further damage to the worktop through the inappropriate use of knives, screwdrivers, scissors, etc. is prevented. This also reduces the risk of personal injury to customers. Carrierpac provides carrying handles that make lifting and handling easier, reducing the risk of personal injury to packing and delivery teams from trapped fingers and back problems. The Carrierpacs had unique numbers (1–500) for the trial enabling trip numbers to be monitored against each individual Carrierpac. Towards the latter stages of the trial, the majority of Carrierpacs were lost. This was due primarily to inadequate briefing of replacement staff at the third-party logistics company handling B&Q’s returns infrastructure and staff at the additional local delivery out-bases brought into the trial. This problem highlighted the need for effective training, awareness, monitoring and incentives to ensure effective operation of closed loop returnable transit packaging. With better controls (e.g. using barcodes or radiofrequency identification (RFID) on each Carrierpac), the project team is confident this project demonstrates the commercial viability of a switch from single-trip cardboard to multi-trip Carrierpacs. The trial has prevented around 8 tonnes of single-trip cardboard packaging from entering the domestic waste stream and resulted in no kitchen worktops being scrapped due to damage. If adopted by B&Q for all its kitchen worktops, multi-trip Carrierpacs could reduce packaging waste by 1,100 tonnes per year. If the Carrierpac concept was adopted by other leading manufacturers and retailers of kitchens, this figure would rise to over 5,000 tonnes per year. As well as confirming that the Carrierpac was fit for purpose, the trial identified the variables that will determine its commercial viability. These include the:

relative purchase cost of the single-trip packaging versus Carrierpac; number of reuses of Carrierpac that can be achieved; loss rate of Carrierpacs per delivery cycle; difference in product damage rates between single-trip packaging and Carrierpac; time and resources required for packing and handling using single-trip packaging versus Carrierpac; cost of operating a closed loop system to track, inspect and clean Carrierpac; and length of time taken for the Carrierpac to complete each distribution and return cycle.

It was found that the breakeven point for a given cost of single use packaging is dependent on the value of the worktop, due to the cost benefits accrued through reduced product damage. As a result, tightly controlled logistics and tracking were identified as critically important in determining the commercial viability of the bags. Following this trial with WRAP (Waste & Resources Action Programme), B&Q plans to roll-out multi-trip packaging for its kitchen worktops and is also considering using multi-trip packaging for other products, particularly those with high rates of product damage.


Contents 1.0 Introduction ............................................................................................................................. 6

1.1 The packaging challenge........................................................................................................6 1.2 The current situation .............................................................................................................6 1.3 Kitchen worktops...................................................................................................................7 1.4 Requirements for a new packaging format ..............................................................................8

2.0 Proposed packaging solution – Carrierpac............................................................................... 9 3.0 Trial objectives, partners and methodology .......................................................................... 11

3.1 Trial objectives ....................................................................................................................11 3.2 Trial partners ......................................................................................................................11 3.3 Trial methodology................................................................................................................12

3.3.1 Carrierpac fitness for purpose ..................................................................................12 3.3.2 Training .................................................................................................................12 3.3.3 Carrierpac trial for 3 m kitchen worktops ..................................................................12 3.3.4 Carrierpac trials for 3.6 m kitchen worktops and breakfast bars .................................13

4.0 Findings and results ............................................................................................................... 14 5.0 Analysis and discussion.......................................................................................................... 16

5.1 Carrierpac reuse rates..........................................................................................................16 5.1.1 Loss of Carrierpacs..................................................................................................16 5.1.2 Speed of closed loop cycle.......................................................................................16 5.1.3 Improving reuse rates .............................................................................................16

5.2 Carrierpac performance .......................................................................................................17 5.2.1 Damage levels ........................................................................................................17 5.2.2 Cleanliness .............................................................................................................17 5.2.3 Moisture protection .................................................................................................17 5.2.4 Materials ................................................................................................................17 5.2.5 Design features ......................................................................................................18

5.3 Waste reduction ..................................................................................................................18 5.4 Cost benefits .......................................................................................................................18

6.0 Conclusions ............................................................................................................................ 20 Appendix 1 Schematic of the B&Q home delivery network................................................................ 22 Appendix 2: TNT/Salvesen process flow chart produced of Carrierpac monitoring .......................... 23 Appendix 3: Monitoring and results spreadsheet with trip numbers of each Carrierpac................... 24 Appendix 4: Cumulative Cost Comparison of single-trip packaging versus Carrierpac ..................... 25 Appendix 5: Carrierpacs in action during the trial ............................................................................. 28


1.0 Introduction 1.1 The packaging challenge Kitchens are the second largest product category (after paint) at B&Q. Kitchen worktops are an essential part of any kitchen sold, but require significant packaging to avoid transit damage and scuffing of the worktop corners, edges and presentation surface. The slightest dent or scratch is likely to lead to the worktop being rejected by the customer, returned to B&Q and scrapped. At a retail price of between £27 and £830 per kitchen worktop, minimising product damage is essential to avoid the wasted cost of production, distribution and disposing of damaged and unsaleable stock. B&Q has been home delivering kitchen worktops to customers for the last four years through its Showroom Fulfilment Centre at Branston, Burton-upon-Trent, Staffordshire. In that time, one design of corrugated board transit packaging has been developed and implemented for all worktop size and weight variations. Customer satisfaction is a key focus across the B&Q organisation. It is B&Q’s aim to achieve 100% success in delivering every product in first class condition on time and in full. B&Q first approached Outpace three years ago for assistance in designing a multi-trip package that could carry the very heavy, awkward but potentially expensive kitchen worktops. At this time, B&Q had identified that damage rates to kitchen worktops was unacceptably high. This led to:

expensive replacement costs; high wastage figures in terms of both worktops and packaging; customer dissatisfaction due to the inconvenience and delays in receiving a pristine new worktop; and increasing numbers of staff required to deal with customer complaints and handle returned products and fulfil

replacement deliveries.

Although a medium-term solution was seen to be a multi-trip reusable package, the short-term solution to reduce the cost of product damage was for B&Q to double the amount of cardboard around each worktop. This almost doubled the packaging cost, increased the packaging weight to 3.2 kg and doubled the compliance costs under the Producer Responsibility Obligation (Packaging Waste) Regulations. The increased thickness of corrugated board used for home delivery has reduced damage levels. This has increased packaging costs, requires additional storage space for the packaging material in the warehouse and takes time for operatives to pack a kitchen worktop into when preparing orders for delivery. B&Q therefore sought a packaging solution that could address these issues. 1.2 The current situation The current transit packaging method for a B&Q kitchen worktop is designed to protect it for just a single journey from the B&Q Showroom Fulfilment Centre to the customer’s home. The packaging consists of an individually printed, large die cut corrugated board wrap. The worktop is shrink-wrapped in plastic film and placed inside the carton; the carton is then folded around the worktop and plastic tape applied. An information leaflet is taped to the outside of the carton to identify the product inside the pack. Figure 3 shows the current packaging. The current process adds packing time and costs at the Showroom Fulfilment Centre, where home delivery orders are prepared. It also results in additional bulky packaging for the customer to dispose of, which is unlikely to fit into typical household recycling or general waste bins.


Figure 3: Current cardboard packaging, sealed with plastic tape

The route to the customer can be complicated involving:

up to a three-day return journey for more remote deliveries, and s.

Appendix 1 shows the supply and distribution model for getting a worktop to the customer.

&Q currently delivers thousands of worktops per week, resulting in around 1,100 tonnes per year of packaging

.3 Kitchen worktops

&Q has three main worktop formats, offered in a variety of specifications (Table 1). Worktops are generally 60

orktops are delivered in a palletised format to B&Q from suppliers, with a plastic shrink film protective cover for

able 1 shows the range of worktop size specifications at B&Q. If the packaging solution proposed by Outpace

ides a

several regional distribution hubs run by B&Q’s logistics contractor

Bentering the household waste stream. In additional, at an average weight of 60 kg, any damaged worktops create significant commercial waste disposal costs in addition to their cost of manufacture and distribution. 1 Bcm wide and 4 cm thick, with two common lengths of 3 m and 3.6 m. The range of breakfast bars is increasing, introducing a wider 90 cm worktop but only 2 m long. Worktops range in weight from 45 kg up to 100+ kg for marble and granite; the average weight is around 60 kg. There is also a wide retail price range from £27 up to £830. Weach worktop. Corrugated board is then added to each worktop at the Showroom Fulfilment Centre when products are picked and prepared for home delivery. T(the ‘Carrierpac’ – see section 2) was adopted for all 19 worktop variants, eight different new packaging specifications (indicated by ‘Yes’ in the final column) would be required to ensure that the packaging provsecure fit around the worktop dimensions.

Reusable ‘Carrierpac’ for kitchen worktops at B&Q 7

Table 1: Current worktop range would require eight new packaging specifications (*)

Ref Natural wood work surfaces width (mm) depth (mm) height (mm) Price from Highest Value1 Worktop 3000 600 40 £320.00 £480.00 Yes2 Breakfast bar 3000 640 40 £320.00 £480.00 Yes3 Breakfast bar 2000 920 40 £360.00 £530.00 Yes4 2m Worktop with sink cut out 2000 600 40 £320.00 £490.00 Yes5 3m Worktop with sink cut out 3000 600 40 £420.00 £580.00 Not required6 Island unit 1570 960 40 £750.00 £830.00 Yes7 Butchers Block 3050 600 27 £165.00 X Yes8 Butchers Block 3000 600 40 £229.00 X Not required

Ref Laminate worktops width (mm) depth (mm) height (mm) Price from Highest Value9 Worktop 3000 600 40 £27.00 £105.00 Not required10 Worktop 3600 600 40 £69.00 £125.00 Yes11 Breakfast bar 2000 920 40 £99.00 £169.00 Not required12 Breakfast bar 3000 665 40 £99.00 £155.00 Yes

Ref Speedstone work surfaces width (mm) depth (mm) height (mm) Price from Highest Value13 Worktop 1800 605 38 £310.00 £350.00 Not required14 Worktop 3600 605 38 £490.00 £580.00 Not required15 Breakfast bar 3600 660 38 £520.00 £620.00 Not required16 Breakfast bar 1800 900 38 £650.00 £720.00 Not required17 Worktop with sink cut out & drainer 1800 605 38 £530.00 £590.00 Not required18 Island unit with sink cut out & drainer 1570 970 38 £750.00 £830.00 Not required19 Island unit 1570 605 38 £570.00 £630.00 Not required

Retail Price

Retail Price

Retail Price

(*) The final column of Table 1 indicates whether the worktop variant requires a new packaging specification. ‘Yes’ indicates that a new specification is required to ensure that the packaging provides a secure fit around the workshop dimensions. ‘Not required’ denotes that the worktop does not require a new packaging specification as this variant shares the same dimensions as a previous worktop listed in the table.

1.4 Requirements for a new packaging format B&Q identified the following requirements for a new packaging format for its range of kitchen worktops:

Reduce and ideally eliminate instances of product damage. The new packaging must provide appropriate protection to the product, particularly to critical areas such as the working surface and ‘bull nose’ edge, ensuring customers receive a pristine product first time. The packaging must also allow the product to be extracted without the use of tools that could both damage the product and increase the risk of personal injury (i.e. avoiding the use of knives).

Reduce costs associated with product damage. Damage in transit results in wastage costs from unsaleable stock and unfulfilled deliveries, and disposal costs of the damaged worktops. This issue is of increasing significance as there is a growing trend towards higher value worktops. The technology involved in making laminate worktops has improved and product costs have risen, which means that the cost of each damaged worktop is even greater.

Match or reduce current packaging costs. The new packaging system must match or beat the current annual costs for corrugated board and tape for the present packaging system.

Match or improve on current packing and handling time. Packing worktops in the current packaging takes two staff 1–2 minutes to handle and pack each worktop for delivery.

Provide an environmentally responsible packaging format. The current packaging format relies on consumers to recycle the corrugated board packaging which, for kitchen worktops, is typically too large for doorstep recycling boxes and bins. This creates inconvenience for customers, who have to transport the packaging to a civic amenity site for recycling or disposal. The packaging must also minimise the environmental impact associated with product damage. This includes the waste of resources used to create worktops that become damaged and unsaleable, and the impact of increased delivery mileage arising from replacing products damaged in transit.

Improve customer experience. The aim is to deliver the purchased product to customers in pristine condition through the use of effective and presentable packaging. This will reduce instances of customer dissatisfaction and complaints relating to damaged goods and delays in receiving a pristine worktop while damaged goods are replaced.

Minimise risk of personal injury. The risk of personal injury during packing and delivery should be minimised through user centric design considerations that particularly address the risks of finger injury and back problems.


2.0 Proposed packaging solution – Carrierpac Before this project, Outpace had contacted several potential manufacturers of packaging to initiate ideas and potential solutions to such a problem. One of these was Storsack UK Ltd (now Storsack Dorton Ltd), which had manufactured a reusable carrying device for the slate tops of pool and snooker tables. Storsack has expertise in the manufacture of woven polypropylene fabric and is the world’s largest manufacturer of woven polypropylene big bags (e.g. for building materials such as aggregate). Outpace and Storsack developed a bespoke design for reusable packaging for B&Q’s kitchen worktop using a two-piece polypropylene (PP) construction. The design incorporates a woven outer and inner liner made of polypropylene Correx®; Outpace and Storsack are joint inventors of this material and have equal ownership of the various European and American patents. The kitchen worktop is secured within the Carrierpac by a Velcro® seal along the full length of the packaging. The Carrierpac is equipped with adjustable carrying handles that enable both vertical and horizontal carrying positions to be used. The woven polypropylene outer is printable, enabling appropriate information to be portrayed including:

branding; delivery team safe handling instructions; and messaging emphasising that the packaging is returnable and reusable.

The ‘inner’ liner is made from 100% reprocessed polypropylene. The ‘outer’ liner uses 3% factory regrinds and currently requires virgin polymer for its strength and tensile properties. Figure 4 shows the construction of Carrierpac and Figure 5 its use to transport a kitchen worktop for B&Q. Figure 4: Carrierpac construction

Heavy duty ‘outer’ PP fabric

Single wall ‘inner’ PP Correx® Figure 5: The returnable and reusable kitchen worktop Carrierpac


Storsack became the main manufacturer of the ‘outers’ for the Carrierpac. Kaysersberg Plastics (part of the DS Smith group) was selected to manufacture the protective corrugated polypropylene ‘inner’ made from Correx®. For the trial, Storsack assembled the Carrierpacs from the two components either in the UK or Turkey, and supplied them to B&Q’s Showroom Fulfilment Centre. Following a successful trial and once the optimum specification has been determined, it may be possible to source the Carrierpac from the Far East. This would reduce costs and therefore the number of reuses required for the Carrierpac to break-even and deliver cost savings compared with single-trip packaging.


3.0 Trial objectives, partners and methodology 3.1 Trial objectives The objectives of the trial were to:

make an average of at least 10 deliveries per Carrierpac before it became exhausted and not fit for further

use;

recycle all Carrierpacs that are no longer robust enough to be reused;

pack, on average, 50 worktops per hour into Carrierpacs;

improve kitchen worktop handling by using the carrying handles inherent in the design of Carrierpacs;

deliver kitchen worktops to the customer in a Carrierpac without incurring any damage to the worktops;

receive good feedback from operatives, drivers, customers, supply chain and logistics relating to the design,

practicalities and performance of the Carrierpac;

identify the prospects for replicating Carrierpac across the sector and to other appropriate product categories;

review the design of the Carrierpac, accommodating feedback from all stakeholders, to improve (if

appropriate) the design, properties and performance of the Carrierpac; and

develop and report a cost benefit appraisal of the Carrierpac upon trial completion based upon the results of

the trial and commercial-scale production of the Carrierpac.

In addition, if the Carrierpac is commercially and technically viable:

to reduce the amount of packaging and product waste entering landfill through the commercial roll-out of

Carrierpac to B&Q kitchen worktops and breakfast bars;

promote the findings of the trial across the sector:

demonstrating the opportunities that returnable transit packaging can bring;

addressing technical issues; and

delivering commercial, environmental and consumer benefits.

3.2 Trial partners A number of organisations were involved in the trial:

WRAP (Waste & Resources Action Programme) provided support for the trials through its waste minimisation

Innovation Fund. This provides support for the development, testing, trial and demonstration of innovative

packaging solutions within the retail supply chain which will reduce household waste.

B&Q is a leading DIY retailer in the UK through its nationwide stores and direct retailing through

www.diy.com. Kitchens represent the second largest product category for the company and therefore

opportunities to improve efficiency, reduce costs and waste within this category are a key priority. B&Q’s

Quality Assurance Team, led by the Packaging Technologist, owned the project within the company.

Outpace is a packaging consultancy specialising in package design, implementation and procurement with a

strong background in environmental expertise concerning the reduction, reuse and recycling of packaging.

Outpace worked with Storsack to develop the Carrierpac packaging format and with B&Q to address the

problems identified with the current packaging and delivery system. Outpace provided management and

administrative co-ordination for the trial, reporting to both B&Q and WRAP.

Storsack Dorton Ltd has expertise in the manufacture of woven polypropylene fabric and is the world’s

largest manufacturer of woven polypropylene big bags (e.g. for building materials such as aggregate).

Storsack developed the Carrierpac concept with Outpace, supplied the woven polypropylene ‘outers’ and

assembled the two-piece Carrierpac for delivery to B&Q.


http://www.diy.com/

Kaysersberg Plastics (part of the DS Smith group) was selected to manufacture the protective corrugated

polypropylene ‘inner’ (Correx®) for supply to Storsack to assemble with the ‘outers’ to form the Carrierpac. TNT1 provides packing, storage and distribution functions to B&Q at its Showroom Fulfilment Centre and

regional distribution centres (out-bases).

Christian Salvesen provides the returns infrastructure for B&Q at its Showroom Fulfilment Centre and has

the task of logging back to stock all the components of a failed delivery. During the trial, Christian Salvesen

staff had to:

unload all the returned empty Carrierpacs; inspect them; clean them; and remove old documents and labels prior to returning the Carrierpacs to TNT for packing and their next

trip.

3.3 Trial methodology 3.3.1 Carrierpac fitness for purpose Carrierpac samples were manufactured for 3 m by 60 cm kitchen worktops and supplied to B&Q during the final quarter of 2005 to check for size and performance. The Carrierpacs were found to be acceptable and 300 were ordered for this particular kitchen worktop specification (chosen because it had the highest sales volume). 3.3.2 Training The trial required training and briefings to individuals throughout the packing, delivery and returns system:

Packing teams were trained on how to:

pack the worktops into the Carrierpac; ensure a good seal on the Velcro closure; and lift and carry the packaged product safely.

TNT supervisors were briefed on logging the usage of Carrierpacs to enable:

the number of reuses to be tracked; and any instances of damage or loss to be recorded.

Delivery teams were briefed on:

handling the packed Carrierpac; unpacking the product; and bringing the empty Carrierpac back to the Showroom Fulfilment Centre.

Christian Salvesen returns teams were briefed on:

collecting and checking the condition of returning Carrierpacs; cleaning and removing old delivery labels; logging returned Carrierpacs; and supplying them to the TNT packing teams for reuse.

3.3.3 Carrierpac trial for 3 m kitchen worktops The first phase of the trial involved 300 Carrierpacs for the 3 m kitchen worktops. All the Carrierpacs included:

a pocket to store product/delivery information; and a label to enable each individual Carrierpac to have a unique number (1–300).

1 TNT Logistics changed its name to CEVA Logistics in 2006.


The Carrierpacs were produced with black carrying loops and incorporated an anti-static treatment in order to maintain their physical appearance. TNT/Christian Salvesen produced a process flow chart to cover all aspects of the trial (see Appendix 2). Christian Salvesen also created a Microsoft® Excel spreadsheet to monitor the number of reuses of each Carrierpac based on its unique number (see Appendix 3). Initial trials involved deliveries from the Showroom Fulfilment Centre direct to local customers – the shortest and most straight forward delivery model. This was found to perform well and the trial was extended to include deliveries further a-field, which incorporated passing through a regional out-base (local distribution centre or ‘hub’). The 3 m trial started in May 2006 and ran until December 06, with monitoring of the performance of the Carrierpacs and regular feedback from all stakeholders throughout. 3.3.4 Carrierpac trials for 3.6 m kitchen worktops and breakfast bars The next phase extended the trial to include 3.6 m by 60 cm kitchen worktops and 2 m by 90 cm breakfast bars. These were selected because each required design modifications that required testing to ensure the integrity of the Carrierpac was not diminished. The size of the 3.6 m Carrierpac required the inner Correx® material to be constructed from two pieces, rather than one, as it became too large for the die cutting tables at Kaysersberg Plastics. The trial sought to test if this modification to the construction would create a weakness in the Carrierpac. For the breakfast bar, the increased width of the product (90 cm rather than 60 cm) affected the positioning of the carrying handles used when carrying the Carrierpac vertically. It also necessitated a different stacking arrangement in stillages on the home delivery vehicles. As with the 3 m by 60 cm Carrierpac, an initial sample of each new Carrierpac size was supplied to ensure correct sizing and function. After approval of the 3.6 m and 2.0 m sample Carrierpacs, 100 of each were manufactured and supplied to B&Q – again with unique identifying numbers (301–500). For ease of identification the 3.6 m Carrierpac had white carrying loops and the 2 m had multi-coloured loops (red, white and blue). The Christian Salvesen spreadsheet (Appendix 3) was extended to cover all 500 Carrierpacs.


4.0 Findings and results Monitoring indicated that not all the Carrierpacs were used during the trial. For example, only 249 of the 300 3 m Carrierpacs were trialled; of the remainder, 26 were destroyed in a fire at the Showroom Fulfilment Centre before the trial began (the fire had no connection with the project). In addition, several Carrierpacs were retained by the project partners to raise awareness and train staff on correct usage, etc. The trial concentrated initially on three major out-bases (Branston, Harlow and Southampton) to give a spread of the different types of handling encountered. The three represented:

the most local route (one day delivery and return); the longest route (three days); and the busiest.

The Carrierpac performed well during this period, with high levels of return. Based upon this very positive response, it was agreed to extend the Carrierpac trial to all 11 out-bases. This resulted in a significant loss of Carrierpacs; it became clear that the additional sites had not been briefed adequately on the Carrierpac and the changed procedures required to operate a closed-loop returnable transit packaging system for the Carrierpac. During the project, it became clear that an improved logging process would allow better data capture and each Carrierpac to be used in more cycles. The actual number of trips achieved is therefore believed to be significantly higher than shown in Table 2. Within the trial period:

the 3.0 m Carrierpacs completed up to 17 trips and averaged almost seven trips; the 3.6 m Carrierpac completed a maximum of 18 trips and averaged over five trips; and the breakfast bar Carrierpac completed a maximum of 14 trips and averaged over five trips.

No damage to worktops delivered in Carrierpacs during the trial was reported by B&Q and no complaints from customers receiving kitchen worktops in Carrierpacs were received. The trial also resulted in around 8 tonnes of cardboard packaging not being used (2,413 trips × 3.2–3.5 kg). In addition, assuming an average worktop weight of 60 kg the avoidance of worktop damage during the trial prevented a further 1.5 tonnes of product waste being created for each 1% reduction in product damage. Per 100,000 kitchen worktops, each 1% reduction in product damage would reduce product wastage by an average of 60 tonnes. During the project, it became clear that not all trips undertaken by the Carrierpac were being logged due to personnel changes within Christian Salvesen during the trial. The actual number of trips achieved is therefore believed to be significantly higher than shown in Table 2. The trial demonstrated that a worktop can be packed into a Carrierpac in 30 seconds compared with around 2 minutes for the cardboard version. However, time is needed to log the Carrierpac, inspect it for cleanliness and damage, remove previous documents/labels and fold it ready for the next trip. Overall, the time required for the Carrierpac system was similar to that for the single-trip system.


Table 2: Summary of Carrierpac usage during the trial

Number of trips made Trip for which Carrierpac used 3 m

worktops 3.6 m

worktops Breakfast

bars Total %

1st trip 249 61 69 379 100 2nd trip 233 44 51 328 87 3rd trip 218 37 43 298 79 4th trip 194 31 41 266 70 5th trip 169 29 37 235 62 6th trip 145 24 33 202 53 7th trip 127 20 30 177 47 8th trip 106 17 23 146 39 9th trip 87 12 17 116 31 10th trip 66 12 11 89 23 11th trip 47 10 9 66 17 12th trip 35 6 7 48 13 13th trip 20 4 1 25 7 14th trip 13 4 1 18 5 15th trip 8 2 0 10 3 16th trip 4 1 0 5 1 17th trip 3 1 0 4 1 18th trip 0 1 0 1 0 Total trips (within trial period) 1,724 316 373 2,413 Average trips per Carrierpac used 6.92 5.18 5.41 6.37

Carrierpac loss rate

0%

20%

40%

60%

80%

100%

120%

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

TripsActual 5% loss per trip 10% loss per trip 15% loss per trip

Figure 6: Graph of Carrierpac loss rate Figure 6 indicates the level of stock replenishment (for Carrierpacs) that may be required under different loss rate scenarios.


5.0 Analysis and discussion 5.1 Carrierpac reuse rates The trial objective was to achieve an average of 10 trips per Carrierpac. During the trial, an average of over six trips was achieved and 17% of the Carrierpacs used completed at least 10 trips (Table 2). No Carrierpacs were damaged to such an extent that they were no longer usable, though six required replacement or repair of the inner Correx®. The reduced number of trips achieved was due to:

Carrierpacs being lost; and Carrierpacs taking longer than had been anticipated to be returned to TNT for repacking with another kitchen

worktop for delivery.

5.1.1 Loss of Carrierpacs There are various stages in the closed loop system where Carrierpacs may have been lost, including being:

left with customers at the point of delivery in error by the delivery team; left with customers at point of delivery due to a customer request to retain packaging; disposed of in error at the out-bases when the delivery teams returned from deliveries; disposed of in error by Christian Salvesen at the Showroom Fulfilment Centre when debriefing returning

vehicles; discarded as damaged without recording that the particular Carrierpac had been destroyed; and stored for long periods at various points within the closed loop operation

Originally each driver was responsible for the return of the empty Carrierpacs; the number and identity of each Carrierpac was recorded and signed for by that driver. If a customer insisted on keeping the Carrierpac, it was agreed that another driver would collect the Carrierpac at a later date. This arrangement was not adopted when the Carrierpacs were sent to out-bases that had not been briefed on the trial and therefore resulted in an increased rate of Carrierpac loss. 5.1.2 Speed of closed loop cycle The speed of operation of the closed loop cycle for returnable transit packaging is a fundamental factor governing the number of packaging units required to control costs and to ensure there are no delays in delivery. The delayed return of Carrierpacs experienced during the trial may have arisen due a number of factors including:

packing staff not always giving priority to using Carrierpacs rather than single-trip packaging for deliveries; delivery teams and out-bases not returning empty Carrierpacs promptly to Christian Salvesen at the

Showroom Fulfilment Centre; slowness of logging, inspecting, cleaning and delivering the returned Carrierpacs to TNT for repacking; and problems with failed deliveries in Carrierpacs becoming stuck in the system.

5.1.3 Improving reuse rates During the trial, a number of possible measures to improve the level of Carrierpac reuse were identified including:

Improved compliance with usage logging. Not all Carrierpac trips were recorded, so the reported figures

are less than the actual number of trips achieved.

Improved training and awareness for staff. Changes in personnel during the trial resulted in a drop in

performance in a number of ways depending on where in the closed loop system the issue arose. This


included Carrierpacs being lost, not logged, underused and stored rather than forwarded to the next stage of

the closed loop cycle.

Incentives and penalties. There is considerable scope for including Key Performance Indicators (KPIs) for

Carrierpac usage and operation of the closed loop system within contractor service agreements.

Recognising Carrierpacs as an asset rather than a consumable. This would help to ensure they are

logged correctly, retrieved from customers and not disposed of in error as waste.

Carrierpac ownership and charges. There are two important issues to consider:

the ownership of the Carrierpacs; whether a per trip fee could be charged to cover Carrierpac purchase and closed loop operation costs

to act as an incentive to the owners to extract maximum value and efficiency from the Carrierpac system.

5.2 Carrierpac performance 5.2.1 Damage levels Six Carrierpacs were damaged to a level where they were removed from service to have a new inner Correx® sheet fitted or repaired. No Carrierpacs were recorded as damaged beyond further use during the trial and no worktops were damaged, demonstrating that the packaging is fit for purpose and capable of multiple trips. Minor surface damage, scuffs, scratches and score marks were found on Carrierpacs but nothing serious enough to merit withdrawing the Carrierpac from the trial. This indicates it may be possible to reduce the specification and cost of the Carrierpac to improve its cost benefit. Eliminating or significantly reducing product damage rates provides the greatest commercial driver for change. If the elimination of worktop damage experienced during the trial can be sustained (particularly for the higher value real wood kitchen worktops), this will provide a strong commercial driver for using the Carrierpacs. So much so, that if zero damage is achieved for the highest value worktops, the Carrierpac becomes cost-effective after only a single trip! In most circumstances, however, these benefits can only be realised by ensuring that Carrierpacs are returned for reuse through full co-operation by all involved, backed up by robust tracking systems that treat the Carrierpac as an asset. 5.2.2 Cleanliness The levels of dirt and dust attraction to the white fabric ‘outers’ was less than expected and acceptable to B&Q. Tests of an alternative material prior to this trial had resulted in higher levels of dirt and dust contamination, and it is appears that the anti-static additive in the current Carrierpac fabric is working well. 5.2.3 Moisture protection A further positive outcome from the trial was that Carrierpacs can stand outside on customer’s driveways or paths on wet ground, or even in the rain, and provide significant moisture protection. The cardboard equivalent would absorb moisture, lose strength and eventually disintegrate. 5.2.4 Materials The inner black Correx® sheets each weigh 1.42 kg and are made from 100% reprocessed polypropylene. This means the Carrierpacs already have about 45% recycled content. Once they have completed a number of trips and are no longer fit for purpose, they are recyclable and the intension is to have them reprocessed either into more Correx® or into household products such as buckets or paint trays. It has been confirmed that the Velcro® seal is polyamide and not polypropylene. The effect of its presence of the recyclability of the Carrierpacs will be tested when they are ready for recycling. Initial consultation with two plastic reprocessors suggests that the minor amount of Velcro® (and adhesive) used in the Carrierpac will not be a significant problem. Adhesives and Velcro® account for less than 1% (by weight) of each Carrierpac.


The PVC document pockets may also cause a reprocessing problem; an alternative polypropylene document pocket has been sourced and will be used for future Carrierpacs. 5.2.5 Design features The Carrierpac was designed to be lightweight and to use the minimum amount of packaging. At 3.2 kg for the 3 m version, this is exactly the same weight as the single-trip cardboard packaging; however, the Carrierpac will perform up to 18 trips and be fully recyclable at the end of its life. Machine-cut Correx® purchased from Kaysersberg was used for the 500 Carrierpacs. These have proved to be good quality, but expensive. Correx® from several other suppliers was trialled in smaller quantities but found to be inferior. A possible cheaper alternative Correx® could be trialled at a later date. The Correx® inners are expensive to set up and trial as Kaysersberg charges for each different size to be manufactured – whether for a one-off sample or thousands. These set-up charges are several hundred pounds each. The same applies to the woven outers, as each one has to be hand produced to fit the inner Correx®. Tolerance on the inner Correx® is just 1 mm, whereas that on the outer polypropylene fabric is 2-3 cm on these long pieces of flexible woven fabric. Unknown to B&Q, TNT changed the delivery method from a vertical ‘toast rack’ arrangement to a horizontal ‘stacking’ method. This meant that the identification (ID) labels could be hidden or trapped between Carrierpacs, thus preventing the trip being recorded. The design of the unique ID tags on the later 200 Carrierpacs (those for 3.6 m and breakfast bar Carrierpacs) was improved and this problem has been resolved. The different stitch pattern used by Storsack for the handle attachment on the 3.6 m and breakfast bar Carrierpacs was not very successful as some handles became detached owing to excessive stitch holes causing the fabric to rip away on certain Carrierpacs. The original stitch pattern as used on the 3 m Carrierpacs performed very well and will be used in future. 5.3 Waste reduction The Carrierpac weight was found to be broadly comparable to the single-trip packaging weight. Table 3 illustrates the cardboard packaging weight saving that would be achieved for a number of annual worktop sales volumes. Table 3: Packaging waste savings from the use of Carrierpacs 3 m

worktop 3.6 m worktop

Weight of corrugated packaging 3.2 kg 3.5 kg 10,000 units 32 t 35 t 50,000 units 160 t 175 t 100,000 units 320 t 350 t 200,000 units 640 t 700 t 500,000 units 1,600 t 1,750 t Exhausted Carrierpacs would need recycling, but it is not clear from the trial results what the annual rate of this recycling and replenishment of Carrierpac stocks would be. 5.4 Cost benefits The economics of using Carrierpacs compared with single-trip packaging depend on a number of variables such as the:

relative purchase cost of single-trip packaging (corrugated cardboard, tape) and the Carrierpac; number of reuses that can be achieved; loss rate of Carrierpacs per delivery cycle; difference in product damage rates between single-trip packaging and the Carrierpac;


time and resources required for packaging and handling using single-trip packaging versus Carrierpacs; cost of operating a closed loop system to track, inspect and clean Carrierpacs; and length of time taken for the Carrierpac to complete each distribution and return cycle.

The key consideration in the commercial viability of Carrierpac will be the extent to which these variables can be predicted, controlled and improved upon. As an example, Table 4 illustrates the issue of commercial viability for the cost of Packaging Recovery Notes (PRNs) necessary to demonstrate compliance with the packaging waste regulations. PRNs equivalent to the obligation for single-trip packaging are required each time it is used, but only for the first usage of reusable packaging. Table 4: Comparative cost of buying PRNs for single-trip packaging and Carrierpac Single-trip packaging For 100,000 3m worktops Weight of single-trip packaging 320 tonnes per year Valpak average PRN price for paper (2006) £9.60 per tonne Cost of packer/filler and seller obligation £1,470 Reusable packaging (Carrierpac) Weight of Carrierpacs required (10 trips per Carrierpac assumed) 32 tonnes Valpak average PRN price for plastic (2006) £28 per tonne Cost of packer/filler and seller obligation £280 Appendix D examines the cost benefits of the Carrierpac versus single-trip packaging when considering a range of scenarios of differing product damage rates, product value and closed-loop operating costs.


6.0 Conclusions Damage to a kitchen worktop during transit to the customer increases costs (wasted cost of manufacturing and shipping the damaged product, the cost of its disposal), increases waste and decreases customer satisfaction. Within the trial period, the highest recorded number of uses of a single Carrierpac was 18 trips. No damage to worktops was reported and no customer complaints were received. The Carrierpac could therefore reduce significantly the number and cost of damaged kitchen worktops and the amount of product waste sent to landfill per year. In addition, the trial has prevented around 8 tonnes of single-trip cardboard packaging from entering the domestic waste stream. If adopted by B&Q for all its kitchen worktops, the multi-trip Carrierpac has the potential to reduce packaging waste by 1,100 tonnes per year. If the Carrierpac concept was adopted by other leading manufacturers and retailers of kitchens, this figure would rise to over 5,000 tonnes per year. As well as confirming that the Carrierpac was fit for purpose, the trial identified the variables that will determine its commercial viability. These include the:

relative purchase cost of single-trip packaging (corrugated cardboard, tape) and the Carrierpac; number of reuses that can be achieved; loss rate of Carrierpacs per delivery cycle; difference in product damage rates between single-trip packaging and the Carrierpac; time and resources required for packaging and handling using single-trip packaging versus Carrierpacs; cost of operating a closed loop system to track, inspect and clean Carrierpacs; and length of time taken for the Carrierpac to complete each distribution and return cycle.

The scenarios developed in Appendix D highlight that the cost benefits of using multi-trip packaging, versus single-trip, accrue sooner for more valuable worktops. It can be seen that the breakeven point for a given cost of single use packaging is dependent on the value of the worktop. For example, under the assumptions set out in the Appendix, cost savings accrue when the Carrierpac is used more than eight times for a £50 worktop, whereas the Carrierpac would only need to be used once to breakeven for a £400 worktop. With an average re-use rate of around 6 times during the B&Q trial, tracking of the bags will be a critical factor in determining commercial viability. The trial demonstrated the technical ability of the Carrierpac to get worktops to customers efficiently with reduced levels of damage. The Carrierpac also provides an enhanced customer experience through the professional presentation of the product upon arrival and offering the unpacked worktop to the customer at the point of delivery. This allows any immediate issues to be resolved (e.g. wrong worktop, obvious damage), enabling the product to be returned immediately and allowing a faster response to failed deliveries. The Carrierpac provides an opportunity to physically demonstrate B&Q’s promotion of sustainable packaging and corporate environmental objectives through on-pack messaging, and clear and simple briefings to delivery teams to respond to customer enquiries during deliveries. Due to the life expectancy of the multi-trip Carrierpacs, printing could be justified to enhance the product image, allow for on-pack promotion of B&Q brand values and provide a quality presentation to customers. The trial demonstrated that a worktop can be packed into a Carrierpac in 30 seconds compared with around 2 minutes for the cardboard version. The Carrierpacs require logging at the returns centre, inspection for cleanliness and damage, removal of previous documents/labels and folding ready for the next trip. Overall the time required made the Carrierpac system similar to the single-trip packaging system. Carrierpac provides carrying handles that make lifting and handling easier (Figure 7). As well as helping to demonstrate compliance with the Manual Handling Regulations, the carrying handles should reduce the likelihood of personal injury to packing and delivery teams from trapped fingers and back problems.


Figure 7: The Carrierpac makes lifting and carrying easier Because no sharp objects are needed to open the Carrierpac, further damage to the worktop from the inappropriate use of knives, screwdrivers, scissors, etc. is prevented. This also reduces the risk of personal injury to the customer or whoever unpacks the worktop. Carrierpacs were found to withstand periods outside on customer’s driveways, paths, etc. with no detrimental effect. If it was, or had been, raining the cardboard in the single-trip packaging would absorb moisture, lose strength and eventually disintegrate. Carrierpacs had unique numbers (1–500) for the trial and trip numbers were monitored against these numbers. Towards the latter stages of the trial, the majority of Carrierpacs were lost. This was due primarily to inadequate briefing of replacement staff at Christen Salvesens and staff at the additional local delivery out-bases brought into the trial. This problem highlighted the need for effective training, awareness, monitoring and incentives to ensure effective operation of closed loop returnable transit packaging. With better controls (e.g. using barcodes or radiofrequency identification (RFID) on each Carrierpac), B&Q is confident this project demonstrates the commercial viability of a switch from single-trip cardboard to multi-trip Carrierpacs.


Appendix 1 Schematic of the B&Q home delivery network


B&Q

SUPPLIER

OUTBASE

SHOWROOMFULFILMENT

CENTRE(SFC)

B&Q STORE

CUSTOMER’SHOME

Direct to Customer

Direct to Store

Supplier to SFC

SFC to Customer - home delivery

Supplier to SFC

SFC to Outbase

Outbase to Store

Store to Customer

SFC to Customer - via home delivery network

Returnable ‘CarrierPac’ - SFC to Customer - via home delivery network

‘CarrierPac’

‘CarrierPac’

Appendix 2: TNT/Salvesen process flow chart produced of Carrierpac monitoring


Carrierpac Returnable Packaging – Process Flow

DE = Despatch D = Drive CS = Christian Salvesens (Returns) T = Transport WA = Warehouse Admin

We will soon be conducting a controlled trial on a returnable packaging solution for the kitchen carrierpac products for home delivery from Branston SFC. The following process will be used during the trial.

From Step 14

1) Despatch DE checks each order for use of Carrierpac.

If there are no Carrierpacs featured no further action is required prior to loading.

2) DE complete ‘Date’, ‘Outbase’, ‘Route’ and ‘Cycle’ sections of D061 Carrierpac Control Sheet

3) DE checks documentation for the ‘SAP Number’ and quote it in the ‘SAP number section’

4) DE checks the longs pack for it’s unique ‘Pack ID number’ (001 to 500) and quotes it in the ‘Pack number’ section

5) DE Repeat steps 3 – 4 with all other longs deliveries on vehicle. To

What if A

There are not enough rows on the D061 Carrierpac Control Sheet

From Step 23

DE to complete all the D061 Carrierpac Control Sheets supplied with load

6) DE completes ‘Despatch Name’ and ‘Despatch signature’ sections of D061 Carrierpac Control Sheet

(7) DE place D061 Carrierpac Control Sheet with TNT Load Plan (Footprint) and send to transport (T).

8) Transport T passes paperwork to Driver



9) Driver D removes customer order from longs return pack at point of delivery.

11) CS check longs return pack numbers against those quoted on the D061 Carrierpac Control Sheet(s).

CS to complete all the D061 Carrierpac Control Sheet supplied with returned Longs Pack

From Step 11

13) CS completes ‘Returns Name’ and ‘Returns signature’ sections

12) CS writes ‘Y’ in the ‘Returned (Y/N) section’

To Step 13

If there are any sleeves missing write ‘N’ in the ‘Returned (Y/N)’ section.

10) D return longs return pack(s) and D061 Carrierpac Control Sheet to Christian Salvesen (CS) on return to Branston.

14) CS pass D061 Carrierpac Control Sheet(s) back to driver.

CS identify problem with pack and decommission Carrierpac from trial. Record on spreadsheet and store redundant Carrierpac away for B&Q QA inspection.

15) CS locate carrierpac pack in storage or supply to DE for next order

16) D pass D061 Carrierpac Control Sheet(s) back to Transport (debrief)



To What if B

T identifies packs that are not returned

17) T checks D061 Carrierpac Control Sheet(s) any identifies longs packs that were not returned

From Step 27

WHEN: Sunday (cycle count)

18) WA conduct physical audit

19) WA Excel – Carrierpac Weekly Audit: Open spreadsheet and complete

20) WA Publish Weekly Audit Report

21) WA instigate retrieval / correction and preventative actions where necessary



What if A: There are not enough rows on the D061 Carrierpac Control Sheet

From Step 5

22) DE get another D061 Carrierpac Control Sheet

To Step 5

23) DE quote the relevant ‘# of #’ at the bottom of all pages

What if B: There are Carrierpacs not returned

From Step 17

24) T If there are any Carrierpac(s) not returned include in Drivers Debrief

25) T Arrange for the missing Carrierpac(s) to be collected

26) D Collect missing carrierpacs and return to CS

To Step 18

27) T Log the collected date in the Carrierpacs Weekly Audit spreadsheet

Appendix 3: Monitoring and results spreadsheet with trip numbers of each Carrierpac


Worktop Carrierpac Status ReportCarrierpac Number Comments / Status 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Carrierpac

NumberCarrierpac

Usage

EXAMPLE 1 Sample has reached 14 trips still live x x x x x x x x x x x x x x x EX 1

EXAMPLE 2 Sample damaged after 9 return trips x x x x x x x x x x EX 2

001 Live x √ √ √ √ √ √ √ √ √ √ √ √ 001 12

002 Live x √ √ √ √ √ √ √ √ 002 8

003 Live x √ √ √ √ √ √ √ √ √ √ 003 10

004 Destroyed in Fire @ Branston x 004 0





















025 Head Office Control Sample x 025 0

026 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ 026 13

027 Live x √ √ √ √ 027 4

028 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ 028 13

029 Live x √ √ √ √ √ 029 5

030 Live x √ √ √ 030 3

031 Live x √ √ √ √ √ √ 031 6

032 Live x √ √ √ √ √ √ √ √ √ 032 9

033 Live x √ √ √ √ 033 4

034 Live x √ √ √ √ √ √ √ √ 034 8

035 Live x √ √ √ √ √ √ 035 6

036 Live x √ √ √ √ √ 036 5

037 Live x √ √ √ √ √ 037 5

038 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ √ 038 14

039 Live x √ √ √ √ √ 039 5

040 Live x √ √ √ √ √ √ √ √ √ 040 9

041 Live x √ √ √ 041 3

042 Live x √ √ √ √ √ √ √ √ √ 042 9

043 Live x √ √ √ 043 3

044 Live x √ √ √ √ 044 4

045 Live x √ √ √ √ √ 045 5

046 Live x √ √ √ √ √ √ √ √ √ √ √ √ 046 12

047 Live x √ √ √ √ 047 4

048 Live x √ √ √ √ √ 048 5

049 Live x √ √ √ √ √ √ 049 6

050 Live x √ √ √ 050 3

051 Live x √ √ √ √ √ √ √ √ √ 051 9

052 Live x √ √ √ √ √ √ 052 6

053 Live x √ √ √ 053 3

054 Live x √ √ √ √ √ √ √ √ √ 054 9

055 Live x √ √ √ 055 3


057 Live x √ √ √ √ 057 4

058 Live x √ √ √ √ √ √ √ √ √ 058 9

059 Live x √ √ √ √ √ √ 059 6

060 Live x √ √ √ √ √ √ √ √ 060 8

061 Live x √ √ √ √ √ 061 5

062 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ √ 062 14

063 Live x √ √ √ √ 063 4

064 Live x √ √ √ √ √ √ √ √ √ √ √ √ 064 12

065 Live x √ √ √ √ √ √ √ √ 065 8


067 Live x √ √ √ √ √ √ √ √ √ 067 9

068 Live x √ √ √ √ √ √ √ √ 068 8

069 Live x √ √ √ 069 3

070 Live x √ √ √ √ √ 070 5

071 Live x √ √ √ √ √ √ √ √ √ √ √ 071 11

072 Live x √ 072 1

073 Live x √ √ √ √ √ √ 073 6

074 Live x √ √ √ √ √ √ √ √ √ 074 9

075 Live x √ √ √ √ √ 075 5

076 Live x √ √ √ √ √ √ √ √ √ √ √ √ 076 12

077 Live x √ √ √ √ √ √ √ 077 7

078 Live x √ √ √ √ 078 4



081 Live x √ √ √ √ √ √ √ √ √ √ 081 10

082 Live x √ √ √ √ 082 4

083 Live x √ √ √ √ √ √ 083 6

084 Live x √ √ √ √ √ √ √ √ 084 8

085 Live x √ √ √ √ √ √ 085 6

086 Live x √ √ √ √ √ √ √ √ √ √ 086 10

087 Live x √ √ √ √ √ √ 087 6

088 Live x √ √ √ 088 3

089 Live x √ √ √ √ √ √ √ √ √ √ √ 089 11

090 Live x √ √ √ √ √ √ √ √ √ 090 9

091 Live x √ √ √ √ √ √ √ √ √ 091 9

092 Live x √ √ √ √ √ 092 5

093 Live x √ √ √ √ √ √ √ √ √ 093 9

094 Live x √ √ √ √ √ √ √ 094 7


096 Live x √ √ √ 096 3

097 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ 097 17

098 Live x √ √ √ √ √ √ √ √ 098 8

099 Live x √ √ √ √ √ 099 5

100 Live x √ √ √ √ √ √ √ 100 7

101 Live x √ √ √ √ √ √ √ 101 7

102 Live x √ √ √ √ √ √ √ √ √ 102 9

103 Live x √ √ √ √ √ √ √ √ √ √ √ √ 103 12

104 Live x √ √ √ √ √ √ √ √ √ √ √ 104 11

105 Live x √ √ √ √ √ √ √ 105 7

106 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ 106 15

107 Live x √ √ √ √ √ √ √ √ 107 8

108 Live x √ √ √ √ √ 108 5

109 Live x √ √ √ √ √ √ √ √ √ √ 109 10

110 Live x √ √ √ √ 110 4

111 Live x √ √ √ √ √ √ √ √ √ 111 9

112 Live x √ √ 112 2

113 Live x √ √ √ √ √ √ 113 6

114 Live x √ √ √ √ √ 114 5

115 Live x √ √ √ 115 3

116 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ √ 116 14

117 Live x √ √ √ √ √ √ √ √ √ √ 117 10

118 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ 118 13

119 Live x √ √ √ √ √ √ √ 119 7

120 Live x √ √ √ √ √ √ √ √ 120 8

121 Live x √ √ √ √ √ √ √ √ √ √ √ √ 121 12

122 Live x √ √ √ 122 3

123 Live x √ √ √ √ √ 123 5

124 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ 124 17

125 Live x √ √ √ √ √ √ √ √ √ √ 125 10

126 Live x √ √ √ √ √ √ √ 126 7

127 Live x √ √ √ 127 3

128 Live x √ √ √ √ √ √ √ 128 7

129 Live x √ √ √ √ 129 4

130 Live x √ √ √ √ 130 4

131 Live x √ √ √ √ √ 131 5

132 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ √ 132 14

133 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ 133 16

134 Live x √ √ √ √ √ √ √ 134 7

135 Live x √ √ 135 2

136 Live x √ √ √ √ √ √ √ 136 7

137 Live x 137 0

138 Live x 138 0

139 Live x √ 139 1

140 Live x √ √ √ √ √ √ √ 140 7

141 Live x 141 0

142 Live x 142 0

143 Live x √ √ √ √ 143 4

144 Live x √ 144 1

145 Live x √ √ √ √ √ √ √ √ √ √ √ √ 145 12

146 Live x √ √ √ √ √ √ √ √ √ √ √ 146 11

147 Live x √ √ √ √ √ √ √ √ 147 8

148 Live x √ √ √ 148 3

149 Live x √ √ √ √ √ √ √ √ 149 8

150 Live x 150 0

151 Live x 151 0

152 Live x √ √ √ √ 152 4

153 Live x √ 153 1

154 Live x √ √ √ 154 3

155 Live x √ √ 155 2

156 Live x √ √ √ √ √ √ √ √ √ √ 156 10

157 Live x √ √ √ √ √ √ √ √ √ √ 157 10

158 Live x √ √ 158 2

159 Live x √ √ √ √ √ 159 5

160 Live x 160 0

161 Live x 161 0

162 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ 162 15

163 Live x √ 163 1

164 Live x √ √ √ √ √ √ √ √ √ √ √ 164 11

165 Live x √ √ √ √ √ √ √ 165 7

166 Live x √ √ 166 2

167 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ √ 167 14

168 Live x √ √ √ √ √ √ √ √ √ 168 9

169 Live x √ √ 169 2

170 Live x √ √ √ √ √ √ √ √ 170 8

171 Live x √ √ √ √ √ √ √ √ √ √ √ √ 171 12

172 Live x √ √ √ √ √ 172 5

173 Live x √ √ √ 173 3

174 Live x √ √ √ √ √ √ √ √ √ 174 9

175 Live x √ 175 1

176 Live x √ √ 176 2


178 Live x √ √ √ √ 178 4

179 Live x √ √ √ √ √ √ √ √ √ 179 9

180 Live x 180 0

181 Live x √ √ √ √ √ √ √ 181 7

182 Live x √ 182 1

183 Live x √ √ √ √ √ √ √ √ √ √ 183 10

184 Live x √ 184 1

185 Live x 185 0

186 Live x √ √ √ √ √ √ √ √ √ 186 9

187 Live x √ √ √ √ √ √ √ 187 7

188 Live x √ √ √ √ 188 4

189 Live x √ √ 189 2

190 Live x 190 0


192 Live x √ √ 192 2

193 Live x 193 0

194 Live x 194 0

195 Live x √ √ √ √ √ √ √ √ √ √ √ √ 195 12

196 Live x √ √ √ √ 196 4

197 Live x 197 0

198 Live x 198 0

199 Live x 199 0

200 Live x √ 200 1

201 Live x √ √ √ √ √ √ √ 201 7

202 Live x √ √ √ √ √ √ √ √ 202 8

203 Live x √ √ √ √ 203 4

204 Live x 204 0

205 Live x √ √ √ √ √ √ √ √ √ √ √ 205 11

206 Live x √ √ √ √ √ √ 206 6

207 Live x √ √ √ √ √ √ √ 207 7

208 Live x √ √ √ √ √ √ 208 6

209 Live x √ √ √ √ √ √ √ √ √ √ √ 209 11

210 Live x √ √ √ √ √ √ 210 6

211 Live x √ √ √ √ √ √ √ √ √ √ √ 211 11

212 Live x √ √ 212 2

213 Live x √ √ 213 2

214 Live x √ √ √ 214 3

215 Live x √ √ √ √ √ √ √ √ √ √ 215 10

216 Live x √ √ √ √ √ 216 5

217 Live x √ √ √ 217 3

218 Live x √ √ √ √ √ √ √ √ √ √ √ 218 11

219 Live x √ √ 219 2

220 Live x √ √ √ √ √ √ √ √ √ √ √ √ 220 12

221 Live x √ √ √ √ 221 4

222 Live x √ √ √ √ √ √ √ 222 7

223 Live x √ √ √ √ √ √ 223 6

224 Live x √ √ √ √ √ 224 5

225 Live x √ √ √ √ 225 4

226 Live x √ √ √ √ √ √ √ √ √ √ √ √ 226 12

227 Live x √ √ √ √ 227 4

228 Live x √ √ √ 228 3

229 Live x √ √ √ √ √ √ √ √ √ √ 229 10

230 Live x √ √ √ √ 230 4

231 Live x √ √ √ √ √ √ √ √ 231 8

232 Live x √ √ √ 232 3

233 Live x 233 0

234 Live x √ √ √ √ √ √ √ √ √ 234 9

235 Live x √ √ √ √ √ √ √ √ √ √ 235 10

236 Live x √ 236 1

237 Live x √ √ √ √ √ 237 5

238 Live x √ √ √ √ √ √ √ √ √ √ 238 10

239 Live x √ √ √ √ √ √ √ √ 239 8

240 Live x √ √ √ √ √ √ √ √ √ √ 240 10

241 Live x √ √ √ √ √ √ √ 241 7

242 Live x √ √ 242 2

243 Live x √ √ √ √ √ √ √ √ √ √ 243 10

244 Live x √ √ √ √ √ 244 5

245 Live x 245 0

246 Live x √ √ √ √ √ √ √ √ √ √ 246 10

247 Live x 247 0

248 Live x √ √ √ √ √ √ √ 248 7

249 Live x 249 0

250 Live x √ 250 1

251 Live x √ 251 1

252 Live x √ 252 1

253 Live x √ √ √ √ √ √ √ √ √ √ 253 10

254 Live x √ √ √ √ √ √ √ √ √ 254 9

255 Live x √ 255 1

256 Live x √ 256 1

257 Live x 257 0

258 Live x √ √ 258 2

259 Live x √ √ √ 259 3

260 Live x √ √ √ √ √ √ √ √ 260 8

261 Live x √ √ √ √ √ √ √ √ 261 8

262 Live x √ √ √ √ √ √ √ √ √ √ √ √ 262 12

263 Live x √ √ √ √ √ √ 263 6

264 Live x √ √ √ √ √ √ √ √ √ √ √ √ 264 12

265 Live x √ √ √ √ √ √ √ √ √ √ 265 10

266 Live x √ √ √ √ √ 266 5

267 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ 267 17

268 Live x √ √ √ √ √ √ √ √ √ √ √ 268 11

269 Live x √ √ √ 269 3

270 Live x √ √ √ √ √ √ √ √ 270 8

271 Live x √ √ √ √ √ 271 5

272 Live x √ 272 1

273 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ 273 15

274 Live x √ √ √ √ √ √ √ √ √ 274 9

275 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ 275 13

276 Live x √ √ √ √ 276 4

277 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ 277 13

278 Live x √ √ √ √ √ √ 278 6

279 Live x √ √ √ √ 279 4

280 Live x √ √ √ √ √ √ 280 6

281 Live x √ √ √ 281 3

282 Live x √ √ √ √ √ √ √ √ √ 282 9

283 Live x √ √ √ √ 283 4

284 Live x √ √ √ 284 3

285 Live x √ √ √ √ √ √ √ 285 7

286 Live x √ √ √ 286 3

287 Live x √ √ √ √ √ √ √ √ √ √ √ √ 287 12

288 Live x √ √ √ √ √ √ √ 288 7

289 Live x √ √ √ √ √ √ √ √ √ √ 289 10

290 Live x √ √ √ √ 290 4

291 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ 291 13

292 Live x √ √ √ √ √ √ √ √ √ √ √ 292 11

293 Live x √ √ √ √ √ √ √ √ √ √ √ 293 11

294 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ 294 15

295 Live x √ √ 295 2

296 Live x √ √ √ √ √ √ √ √ √ √ √ √ 296 12

297 Live x √ √ √ √ √ √ √ √ √ √ √ √ √ 297 13

298 Live x √ √ √ √ √ 298 5

299 Live x √ √ √ √ √ √ √ √ 299 8

300 Live x √ √ √ √ √ √ 300 6SUM 249 233 218 194 169 145 127 106 87 66 47 35 20 13 8 4 3 0 0 0

√ = Received back, yet no copy of outgoing paperwork

√ = Copy of outgoing paperwork not ticked off to confirm receipt back.

√ = ?


Appendix 4: Cumulative Cost Comparison of single-trip packaging versus Carrierpac The graphs presented below show the cumulative costs associated with using single-trip packaging versus a Carrierpac for a range of worktops. A range of scenarios were developed based on the assumptions set out in the table below.

Assumptions:

(i) Cost of card (transit packaging) per trip = £3

(ii) Cost of a Carrierpac = £25

(iii) Cost of tracking Carrierpac and QA per trip = £2

(iv) Product damage rate using card = 6%

(iv) Product damage rate using Carrierpac = 2%

The figures above do not reflect actuals for B&Q; however, the data does enable the costs associated with a range of scenarios to be examined. The scenarios presented below demonstrate the cost effectiveness of using multi-trip packaging versus single-trip, most strikingly for more expensive worktops.


Table A: Cumulative Cost Comparison for single-trip packaging versus Carrierpac

Number of Trips

Cost of Worktop

Scenario 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Not using Carrierpac (cost of card) (i)

£3 £6 £9 £12 £15 £18 £21 £24 £27 £30 £33 £36 £39 £42 £45 £48 £51 £54 £57 £60

Cost of Carrierpac (ii) £25 £25 £25 £25 £25 £25 £25 £25 £25 £25 £25 £25 £25 £25 £25 £25 £25 £25 £25 £25

Cost savings -£22 -£19 -£16 -£13 -£10 -£7 -£4 -£1 £2 £5 £8 £11 £14 £17 £20 £23 £26 £29 £32 £35

Cost of Carrierpac & tracking/QA (iii)

£27 £29 £31 £33 £35 £37 £39 £41 £43 £45 £47 £49 £51 £53 £55 £57 £59 £61 £63 £65

£50 -£22 -£19 -£16 -£13 -£10 -£7 -£4 -£1 £2 £5 £8 £11 £14 £17 £20 £23 £26 £29 £32 £35

£100 -£20 -£15 -£10 -£5 £0 £5 £10 £15 £20 £25 £30 £35 £40 £45 £50 £55 £60 £65 £70 £75

£400

Cost savings – using Carrierpacs instead of card, taking into account product damage (iv) -£8 £9 £26 £43 £60 £77 £94 £111 £128 £145 £162 £179 £196 £213 £230 £247 £264 £281 £298 £315

Table B Cost savings for single-trip packaging versus Carrierpac

-£50

-£30

-£10

£10

£30

£50

£70

£90

£110

£130

£150

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Trip number

Cum

ulat

ive

cost

Cost savings including product damage - £50 worktopCost savings including product damage - £100 worktopCost savings including product damage - £400 worktop


Appendix 5: Carrierpacs in action during the trial Figures 8 & 9: Transit packaging - cardboard used to box worktops for delivery (prior to the use of Carrierpacs)

Figures 10 & 11: Worktops stored at Branston distribution centre prior to delivery

Figures 12 & 13: Carrierpacs being unfolded and packed during the trial


Figure 14: Empty Carrierpacs, folded and ready for another trip

Figures 15-16: Several methods of internal handling and delivery were employed including: the use of metal cages, where they were stood upright (toast racked); 4 post metal stillages, where they were laid flat or toast racked; and pallets.

Figures 17-18: Several methods of internal handling and delivery were employed including: the use of metal cages, where they were stood upright (toast racked); 4 post metal stillages, where they were laid flat or toast racked; and pallets.



Figure 19: Carrierpacs being handled onto various vans and lorries

Written by: Tim Hutchinson of Outpace Ltd Greg Alder of B&Q

Published by Waste & Resources The Old Academy Tel: 01295 819 900 Helpline freephone Action Programme 21 Horse Fair Fax: 01295 819 911 0808 100 2040 Banbury, Oxon E-mail: [email protected] OX16 0AH www.wrap.org.uk

Documents

Retail Innovation– Final Report Reusable ‘Carrierpac ... - reusable... · worktops and 100 Carrierpacs designed to carry a 2 m long by 90 cm wide breakfast bar worktop. These