Varroc Lighting Systems Export Packaging Guidelines (12-01

Varroc Lighting Systems Export Packaging Guidelines

For Intercontinental Shipments to Varroc Lighting S ystems

Released: 12/1/2012

Overview This guideline replaces and supersedes any and all previous editions. The guideline is for all purchased part suppliers making Intercontinental shipments into all Varroc Lighting Systems manufacturing facilities globally. If there is a viable and documented business reason for a deviation from these guidelines, the purchased part supplier must receive approval from the receiving Varroc Lighting Systems facility. Varroc Lighting Systems facilities may have specific regional and local requirements that should be considered in addition to these guidelines. In cases where the local Varroc Lighting Systems facility has supplemental guidelines, the more severe, most strict guideline will apply. Questions regarding these guidelines should be directed to Varroc Lighting Systems Packaging Engineering:


Released: 12/1/2012 This is an uncontrolled document when printed.

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Contents

1.0 Introduction

2.0 General Requirements

3.0 Supplier Requirements

4.0 Varroc Lighting Systems Supplier Packaging Data Form (1121)

5.0 Standard Pallets and Containers

6.0 Acceptable and Unacceptable Examples

7.0 Wood Packaging Material

Appendix:

A Container Selection Flow Chart

B Supplier Checklist



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1.0 Introduction These Guidelines have been prepared to assist purchased part suppliers in meeting the Varroc Lighting Systems Export Packaging requirements as well as normal transportation and handling to help insure part quality for intercontinental shipments to all Varroc Lighting Systems manufacturing locations globally. Purchased part suppliers are obligated to insure that they are informed about the latest requirements and that all shipments to Varroc Lighting Systems are compliant.

Due to the significant importance to Varroc Lighting Systems’ operations, compliance to these packaging requirements is mandatory and will be continuously monitored. Non-compliance to the instructions contained in this manual will be brought to the supplier’s attention for immediate resolution. Any incremental costs generated by non-compliant packaging may be billed back to the suppliers shipping location. Any persistent violations or recurring problem will be referred to the appropriate Varroc Lighting Systems buyer for corrective action as necessary.



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2.0 General Requirements Regardless of packaging material, style of packaging, the ship from or ship to locations, these general requirements will be in effect. Purchased part suppliers should review and insure all packaging is in line with these expectations. 2.1 Part Quality The purchased part supplier is responsible to insure their packaging delivers their part to the final point of use, in a production ready and damage-free condition, assuming normal handling, transportation, storage, and in-plant movements.

Varroc Lighting Systems will provide packaging approval based off the container selection, container size, container density, and overall design to help insure in plant requirements are met. The purchased part supplier is responsible for the design and development of the production packaging to fit all variants and design levels of the

sourced part and to insure the part quality is maintained to the final point of use. The supplier is responsible for providing adequate protection of their parts. Some packaging systems and components may require additional protection such as corrosion, surface abrasions, or static build-up. The use of preservatives or other special packaging must be reviewed and concurred by the receiving Varroc Lighting Systems facility prior to adoption. 2.2 Packaging Materials Whenever possible, easily recyclable and/or reusable material should be used: such as paper corrugated containers and wood pallets. Certain non-recyclable materials can be more difficult and costly to recycle or dispose of, such as foamed plastics, and therefore should only be used when no suitable substitute is available. Due to material properties, Expanded Polystyrene (EPS) in its natural compound state is not preferred as a packaging material and should not be used without prior approval by the receiving Varroc Lighting Systems facility. Suppliers must also insure that materials are easily separated for recyclability. For example, foam pieces glued to a paper corrugated sheet can be difficult to separate and properly recycle. Metal banding must not be used unless authorized in writing by the receiving Varroc Lighting Systems facility. 2.3 Manual Handling The gross weight of containers designed for hand carrying and handling shall not exceed 12 kilograms (26.5 pounds), even if palletized. Gross weight is the weight of the product plus the weight of the packaging materials.



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Any deviation from these weight limits must be approved in writing by the receiving Varroc Lighting Systems facility. Standard ergonomics guidelines must be considered during the packaging development process. Purchased part suppliers should confirm their proposal meets all local, country and regional ergonomic requirements. 2.4 Government Regulations It is the purchase part supplier’s responsibility to insure that all packaging conforms to all government and transportation rules and regulations for the ship from location and the ship to location. 2.5 Packaging Quantities Packaging design and part counts (pieces per container) shall not vary and containers should always be shipped with full container quantities except when authorized by the receiving Varroc Lighting Systems facility and should be marked accordingly. One container shall hold only one part number. Mixed loads are only acceptable with prior approval from the receiving Varroc Lighting Systems facility. 2.6 Load Stability All packs must have sufficient vertical strength and stability to withstand tiered heights to help minimize freight and storage cost. Proper unitization is critical to insure maximum load stability. Stretch/shrink wrap is a preferred method of unitization. Banding, seatbelts or other stabilizing techniques can be utilized to secure palletized loads. The supplier must insure their method will provide the required unitization and stabilization. Nailing, stapling or gluing is not an acceptable method for securing the loads. Shipping Unit Loads must be able to be stacked 2200mm (86”) high in storage and in transit. No pyramid loads are ever acceptable as they reduce the load stackability, will not allow Varroc Lighting Systems to maximize freight, and risk product damage. Containers must be oriented so that they will fully utilize the length and width of the pallet. To help insure vertical integrity containers must not overhang the edge of the pallet



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2.7 Packaging Design Overall pallet/unit load sizing should help maximize shipping density and minimize the necessity for blocking and bracing. The proposed packaging must conform to the mode of transportation designated by Varroc Lighting Systems. Every effort should be made to minimize the cost of transportation. Individual requirements for unique usage environments should be considered during packaging development. Some receiving locations have special requirements, which may limit the maximum size and weight (for example, items stored in facilities with automated storage and retrieval systems, or special storage racks systems). For help in choosing the correct containers size, refer to the Container Selection Flow Chart in Appendix A of this guideline. For Cross-Docked material there will be additional packaging requirements. Please contact Varroc Lighting Systems Packaging Engineering for assistance. 2.8 Hazardous Materials Transport regulations will vary for hazardous materials depending on the transportation mode. Hazardous materials shipped to any Varroc Lighting Systems facility must comply with all applicable international and local regulations and be accompanied by the necessary shipping documentation and safety data sheets. It is the purchased part supplier’s responsibility to pack any hazardous materials in appropriate approved packaging and to label and mark all unit loads containing hazardous materials according to regulations. 2.9 Environmental Considerations Expendable container systems should be designed and engineered for use within reasonable and foreseeable environmental conditions. The receiving Varroc Lighting Systems facility can provide specific restrictions on time frames and expected order rates. In order to be kept clean some parts may require additional protection during transportation, storage, and/or plant environment. Expendable container systems should be designed to withstand a wide variation in temperatures from -35°C to +65°C (-30°F to +150°F) and high humidity (up to 90%) during handling, transit and storage. Material can also be in storage for up to 6 months in some cases. 2.10 Transportation Considerations Packaging must be designed for transport logistics that are common for overseas supply chains. Suppliers should consider all possible modes of transit including truck, rail, ocean and potentially air freight.



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2.11 Pallet Surface and Cube Utilization The pallet surface utilization is critical to insure pallets can be consolidated and stacked properly. Proposed cartons should cover a minimum of 90% of the pallet surface (FYI – all cartons listed in Section 5.2 meet this requirement). If the proposed packaging does not meet this minimum target it may be rejected and a better proposal requested.

For all intercontinental shipments Varroc Lighting Systems Transportation has the goal to utilize a minimum of 90% of the available shipping space inside the sea container. If the proposed packaging does not meet this minimum target it may be rejected and a better proposal requested.

2.12 IMC Packaging Suppliers

If required, Varroc Lighting Systems can provide regional contacts to preferred suppliers for IMC packaging. Preferred suppliers can also be found on the PICS website. Please contact Varroc Lighting Systems packaging engineering for more information.



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2.12 Quick Reference Guide

Do Deviation Don’t

Con

tain

er

Choose a standard IMC carton from this guideline

Use recyclable materials

Insure weight limits are not

exceeded for manually handled containers (12 kg /

26.5 lbs)

Insure packaging will protect part quality

Insure the appropriate

strength material is being used

Films, plastic bags and foam sheets should be

avoided if possible

Wax coated paperboard or corrugated should not be

used unless required

EPS foam (polystyrene) should not be used

Foam glued to corrugated

should not be used

Un-recyclable materials should not be used

Pal

let

Insure proper pallet size is being used:

1140mm x 980mm x 125 mm (45” x 39” x 5”)

Insure your Solid Wood

Packaging is ISPM Certified and marked accordingly

Alternate size pallets should only be used when required due to part size.

Corrugated, molded pulp, plywood, particle board,

laminate and metal pallets should only be used if a treated alternative is not

available

There should be no protruding objects or sharp

edges on the pallets

Shi

ppin

g U

nit L

oad

Overall design should allow for the best space utilization

possible

Shipping Unit Load Height should not exceed 1100mm

(43”)

Insure that your stretch wrap/plastic banding is

being used properly

Make sure your 1121 form is submitted and approved

via the PICS website

Any use of wood supports should be minimized or replaced with paper or

corrugated material

Confirm acceptance of any deviations in writing

Wood crates should not be used

Do not use any nails,

staples, or metal banding to attach large cartons to the

pallet

No pyramid Pallet loads should ever be shipped

Pallet loads should have no

overhang

Excel based 1121 forms are no longer acceptable



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3.0 Supplier Requirements

3.1 Supplier Responsibility Each supplier is responsible for the design of their product packaging and for ongoing adherence to the Varroc Lighting Systems Export Packaging Guidelines to insure that their product is transported and received at the Varroc Lighting Systems manufacturing location in quality approved condition. 3.2 Packaging Approval The supplier is responsible to insure that all packaging has been approved prior to any production shipments being made. 3.3 Packaging Testing Suppliers are responsible for any testing required to insure their product packaging will perform as required. If possible, testing should be done prior to any shipments being made to insure the robustness of the proposed packaging design. Suppliers can contact Varroc Lighting Systems Packaging Engineering for assistance to determine the proper testing protocol to help insure the proposed packaging will be sufficient. Varroc Lighting Systems Packaging Engineering maintains the right to approve the test protocol in certain cases as needed. 3.4 Supplier Checklist To insure that you have used the Varroc Lighting Systems Export Packaging Guidelines properly the Supplier Checklist located in Appendix B at the end of this guideline should be utilized to confirm all critical items have been completed. It is recommended this page be printed and used for each unique part being shipped. 3.5 Alternative Solutions If a lower total cost solution exists that is not compliant with these guidelines the supplier should contact Varroc Lighting Systems and provide an analysis for review. In some cases returnable, durable, and pooled containers may provide a benefit for intercontinental shipments and can be reviewed on a case by case basis.



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4.0 Varroc Lighting Systems Supplier Packaging Data Form (1121)

Varroc Lighting Systems has utilizes a web based packaging data form which can be filled out and submitted electronically. It is mandatory that all purchased part suppliers utilize this system.

http://pics.varroclighting.com

Varroc Lighting Systems will provide packaging approval based off the container selection, container size, container density, and overall design to help insure in plant requirements are met. The purchased part supplier is responsible for the design and development of the production packaging to fit all variants and design levels of the

sourced part and to insure the part quality is maintained to the final point of use. Screen shot from Varroc Lighting Systems PICS:



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5.0 Standard Pallets and Containers 5.1 Standard Intercontinental Pallets The pallet size is predicated on commonly used sea container interior dimensions:

• Width: 2337 mm (92”) • Minimum door opening height: 2286 mm (90”) • Lengths:

� 5,892 mm (232”) - 20 foot container � 12,014 mm (473”) - 40 foot container

The recommended AIAG pallet size for Intercontinent al shipments is 1140mm x 980mm x 125mm (45.0” x 39.0” x 5.0”) +0/-6 mm for the length and width (1/4”) +5/-5 mm for height (3/16”) The AIAG standard pallet footprint shall be used for all intercontinental shipments to Varroc Lighting Systems Regardless of style, all pallets must allow for 4-way access to aid in the handling and storing of each unit load. Winged pallets should not be used. Acceptable Pallet Styles:

• Block Style Pallet with full perimeter bottom



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• Block Style Pallet without full perimeter bottom

• Runner (Stringer) Style Pallet.



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5.2 Standard Intercontinental Carton Sizes The sizes listed below are the most common standard Varroc Lighting Systems carton sizes to be used for Intercontinental shipments. Other sizes can be used but must properly and efficiently cube out the export pallet footprint. The full unit load height, including the pallet and all cartons, can not exceed 1100mm (43”). The Container Selection Flow Chart in Appendix A of this guideline should be used to help select the proper size carton.

IMC Carton Number

Exterior Dimensions CARTON SPECIFICATIONS

(mm) (in) Burst Strength BCT

L W H L W H (kPa / PSI) Kg

IMC010 140 240 120 9.5 5.5 4.75 1320 (275) 208

IMC020 140 240 240 9.5 5.5 9.5 1320 (275) 208

IMC030 280 240 120 11 9.5 4.75 1320 (275) 243

IMC040 280 240 240 11 9.5 9.5 1320 (275) 243

IMC050 280 480 120 19 11 4.75 1320 (275) 294

IMC060 280 480 240 19 11 9.5 1320 (275) 294

IMC070 560 240 120 22 9.5 4.75 1320 (275) 301

IMC080 560 240 240 22 9.5 9.5 1320 (275) 301

IMC081 560 375 240 22 14.75 9.5 1320 (275) 630

IMC090 560 480 120 22 19 4.75 2180 (275) 692

IMC100 560 480 240 22 19 9.5 2180 (400) 692

IMC110 560 480 480 22 19 19 2180 (400) 692

IMC120 560 960 120 38 22 4.75 2470 (275) 737

IMC130 560 960 240 38 22 9.5 2800 (500) 1179

IMC140 560 960 480 38 22 19 2500 (500) 1074

IMC150 1120 480 120 44 19 4.75 2470 (275) 952

IMC160 1120 480 240 44 19 9.5 2500 (500) 1102

IMC170 1120 480 480 44 19 19 2500 (500) 1102

IMC180 1120 960 240 44 38 9.5 3524 (500) 1950

IMC190 1120 960 480 44 38 19 3524 (500) 1950

IMC193 1120 960 560 44 38 22 3524 (1100) 1950

IMC197 1120 960 600 44 38 23.6 3524 (450) 1950

IMC197HC 1120 960 730 44 38 29.2 3524 (450) 1950

IMC200 1120 960 960 44 38 38 3524 (450) 1950

Note: The Specifications listed in this guideline are minimum recommendations. Suppliers are responsible for part quality and may need to adjust these factors as required. Outside dimensions must remain consistent to insure full utilization of the export pallet and sea containers.



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5.3 Carton Performance Stacking strength shall be a value that adequately protects the contents of the carton through a complete transport cycle. Carton stacking strength shall be verified through a Box Compression Test (BCT). Hand holes in cartons reduce BCT values and may require stronger material. Carton toughness shall be specified with a minimum value that adequately protects the contents of the carton through a complete transport cycle. Carton toughness shall be verified for corrugated fiberboard through a Burst Strength (BS) test. This minimum value assures performance when the carton is shipped either non-palletized or in a pallet-loads of mixed cartons. Other factors that need to be taken into consideration that can degrade carton performance include: Leaking sea containers Multiple shipments of product Long term storage



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5.4 Pallet Loading Cartons are to be palletized in full layers only (no "pyramiding"), to allow tiered unit loads in transit and storage. If release quantities are inadequate to complete full layers, additional cartons must be shipped empty (and marked as “empty”) in order to complete a full layer. Suppliers must size all cartons to fully utilize the length and width of the pallet. Cartons must not overhang the pallet base. Shipping unit loads should not exceed 1100mm (43”), including the pallet, when fully loaded.

5.5 Expendable Carton Closures Strippable reinforced tape or spot gluing are the only acceptable methods for carton closure. If gluing is selected, glue transfer to the part surface is unacceptable.



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5.6 Styles of Corrugated Containers

Regular Slotted Container (RSC): FEFCO Code - 0201 Top and bottom are of equal length; folded flaps meet only if box is square.

Half Slotted Container w/Cover: FEFCO Code – 0312 Hand-Held Carton Style: Consists of a half slotted container with a lid. Can be used as combination shipper and shelf package and for various applications where cover must be removed and replaced.



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Bulk / Pallet Box Style: Consists of a half slotted container with a lid. Should be used for larger components. Can be made with a perforated drop-down door to aid in the loading and unloading of the components.

Pallet Box Style Containers: FEFCO Code - 0310 Consists of a top and bottom tray with a tube style body. Should be used for larger components. Can be made with a perforated drop-down door to aid in the loading and unloading of the components.



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6.0 Acceptable and Unacceptable Examples The information below is meant to help illustrate to the Varroc Lighting Systems supplier what is considered acceptable and unacceptable by providing examples of actual shipments. 6.1 Acceptable Proper Stacking on pallet, Proper Unitization

Proper material strength, Proper utilization of space (cube utilization)

Proper Banding



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6.2 Unacceptable Improper Unitization – cartons have shifted Improper strength material, overhang

Cartons are not sized to pallet properly, overhang Cartons are overhanging the pallet

Improper markings – cartons/pallet loads must be able to stack up to 2,200mm (86”)



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Pyramid loading Pyramid loading, improper pallet

Pyramid loading Pyramid loading, improper height

Improper Banding Wood Crates



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7.0 Wood Packaging Material All wood packaging material must follow all local and international guidelines and it is the supplier’s responsibility to insure their material is compliant with the most up to date requirements. ISPM15 The ISPM15 guideline covers all forms of solid wood packaging material (SWPM) that may serve as a pathway for pests posing a risk mainly to living trees. Included under this guideline are wood packaging material such as crates, boxes, packaging cases, dunnage, pallets, cable drums and spools/reels, which can be present in almost any imported consignment, including consignments that would not normally be subject to phytosanitary inspection. Not covered under this guideline is processed wood material that is processed in such a way that is free from pests (e.g. plywood). There are also other materials that can be considered that do not require treatment such as corrugated pallets and plastic pallets. All treated material must be marked with an official stamp identifying that the wood is debarked, the type of treatment used, the country where application was done and the registration number of the body which applied it. Symbol – must resemble closely to the example shown below. Country Code – The country code must be the International Organization for Standards (ISO) two-letter country code (shown in the below example as “XX”). Producer / Treatment Provider – A unique code assigned by the NPPO to the producer of the wood packaging material or treatment provided who applies the mark (shown in the below example as “000”) Treatment Code – Treatment code is an IPPC abbreviation for the approved measure used (shown in the below example as “YY”). HT – Heat Treatment MB – Methyl Bromide



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A - Container Selection Flow Chart

The following Packaging Determination Flow Chart is intended to help suppliers with the proper choice of containers and packaging approval process.

Determine the overall size of the component.

Select the smallest recommended standard

carton into which the component fits.

Select the smallest standard bulk box into which the

component fits.

Fill the carton with as many parts as possible.

Fill the pallet box with as many parts as possible.

Does the carton weight more than 12 kg or 26.5 lb

when full?

Does the pallet box exceed the manufacturer's weight capacity

when full?

Submit 1121 for approval.

Contact Packaging Engineering.

Contact Packaging Engineering.

NO

YES

NO

NO

YES

YES

NO

YES

Will the components fit into a standard

carton?

Will the components fit into a standard

bulk box?



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B - Supplier Checklist

To help insure that you have used these Export Packaging Guidelines properly please use the below checklist to review and confirm all critical items have been completed. It is recommended this page be printed and used for each unique part being shipped.

Do you have the most recent Varroc Lighting Systems Export Packaging Guidelines and have you read and understood what is required?

Have you confirmed your selected packaging conforms to the contents of the Varroc Lighting Systems Export Packaging Guidelines?

Have you completed and submitted the Varroc Lighting Systems 1121 form via the PICS website (www.pics1121.com) for approval?

Have you received full packaging approval via the PICS website (the watermark stating “APPROVAL PENDING” will be removed once full approval has been received)?

Do you have an appropriate packaging supplier selected that can provide the correct materials in the correct quantities at the required times?

Has every effort been made to use only packaging material which can be recycled?

Has the appropriate protection methods been reviewed and implemented if necessary for corrosion, abrasion, static build up, etc.?

Does your pallet size comply with the 1140mm x 980mm (45” x 39”) requirement and will your shipping unit loads height be 1100mm (43”) or less (including pallet can cartons)?

Does your packaging meet all government and transportation rules and regulations?

Have all internal processes been documented to insure that all export shipments are shipped to the approved guidelines and 1121 forms?

Were ergonomic requirements reviewed as part of the packaging design process?

Will all palletized loads be properly secured and no steel banding will be used when shipping to Varroc Lighting Systems?

Has testing been performed to help insure your packaging is robust enough to support stacked loads up to 2,200mm (86”) during transit?

Did you insure there will be no overhang on your shipping pallets and there will be no pyramid loads shipping to Varroc Lighting Systems? These are not acceptable under any circumstances.

Is a process in place to insure no shipments will be made with a carton gross weight in excess of 12 kg (26.5 lbs) without prior written approval from the receiving facility?

Documents

Varroc Lighting Systems Export Packaging Guidelines (12-01