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Bulk Packaging Offers Loads of Benefits

Extensive Field Test Indus NEVA System Convinces Jardin

After extensive testing, Jardin has switched to the NEVA system of Indus Integrated Bulk Logistics.
The new bulk packaging has resulted in a calmer and safer work floor. A visit to the garden furniture manufacturer's production plant in Rijen shows that the system has even more benefits.

In the past, the Jardin plant in Rijen used octabins for the storage of raw materials and the supplying of plastic granulate to the various moulding machines. However this octagonal cardboard bulk packaging failed to meet all the wishes and requirements of the garden furniture manufacturer.

"Our greatest concern was safety," explains plant manager Mehmet Turkyilmaz. "Pallets tended to fall over, as the construction was not strong and stable enough. The weight of the plastic granulate, approximately 800 to 900 kilos per bulk packaging, combined with the stacking of the octabins, led to four to seven incidents each year. What's more, it caused 'fear' on the work floor. We are strongly committed to safety. We don't want to run unnecessary risks," Turkyilmaz continues. The plant manager explains that he believes that the bulk packaging had more drawbacks. The cardboard octabins can only be used a limited number of times. "That is not user-friendly," explains Turkyilmaz. "The system also took up a lot of space. Particularly after we decided to no longer stack the octabins to keep them from falling over. At one point, space was so limited that we had to rent additional storage space for our raw materials elsewhere. Something needed to be done."

The Solution

Jardin hired metal frames in which the octabins could be placed, allowing the stacking of bulk packaging again. But this temporary solution was too expensive, explains the manager, which is why they decided to switch to FIBCs. This was a great improvement, but they were not out the woods yet; for example, the large sacks tended to sag on the pallets. That is why Turkyilmaz continued to search for a solution. He found it when he came across an article on the Conbox, as the Indus NEVA system was then known. The flexible storage system for bulk goods immediately appealed to Turkyilmaz. "I liked the tub-shaped upper layer of the specially designed frame. This allows the big bag to empty fully and easily during unloading. This is not the case when you are working with flat pallets; these always require additional work. Nor is additional work needed when processing the raw materials on the production line. Moreover, this new system removes all the safety issues."

Extensive Testing

Turkyilmaz contacted Indus Integrated Bulk Logistics in Veenendaal, which was developing a second generation of systems at the time (see also: 'Second generation' article). As soon as development had progressed sufficiently and a few test models were available, Jardin was the first to test the system in practice.

The manufacturer requested four systems in order for the tests to be as realistic as possible. One of the benefits of the new system is that the bulk goods can be stacked three high. "This means you need a sufficient number of systems in order to test them properly," says Turkyilmaz.

But the new system was tested even further. Turkyilmaz: "Again, safety was paramount. We measured the sagging of the products and the stability, robustness and rigidity. But we also looked at user-friendliness. Three forklift truck drivers from each team, 15 drivers total, worked with the system for two weeks. We looked at how easy it was to pick up and move the systems, and analysed the unloading of plastic granulates."

Peace and Safety Restored

The positive feeling Turkyilmaz had when reading the article was confirmed by the test, which meant the manager needed to secure financing. The plant manager continues, "After all, this involved an investment of more than 50,000 Euros, but luckily the board of directors understood the necessity." Jardin purchased 250 systems in total. These have now been operational for over six months, and make full use of all of the system's applications (filling, storage and unloading). "The system suits us perfectly." Turkyilmaz' reaction is brief and to the point. "During the test, the system sometimes sagged slightly too much, which has been resolved by reinforcing the metal frame.

Indus also resolved some other issues [a non-slip material has been added to the bottom of the pallet deck to prevent the load from sliding, Ed.], which, according to Turkyilmaz, means that no more adjustments are required. However, Jardin did need to make some minor adjustments to the production lines to achieve the best possible result with the new system. For example, the system is placed on a frame during unloading for safety reasons. The results say it all. The number of incidents has gone down dramatically and peace has returned to the work floor, in both the storage and in the production areas. "Everyone is extremely happy," enthuses Turkyilmaz.

Second Generation

Over a year after having introduced the Conbox, Indus Integrated Bulk Logistics presented Indus NEVA, a second, more widely useable version of the bulk storage system. The system is not only different in name. The design of the storage system was reassessed on the basis of the experiences in the market. The stability and the rigidity were improved by using differently shaped ribs and a metal-reinforced frame. The changes have greatly increased the load capacity. The second generation offers a storage volume of 2m and a maximum load capacity of 2 tons for FIBCs with a maximum height of 2,000mm. The maximum stacking capacity of the new system is 6,000kg. This means that a maximum weight of 4,000kg can be placed on the lower system. Thus, the maximum storage capacity is 6m, or 6,000kg per 1.4m.

Who, What, Why?

Who? Jardin has been manufacturing plastic garden furniture for more than 40 years. The plant in Rijen manufactures approximately five million garden furniture items annually.

What? Jardin has recently started using the Indus NEVA system for the filling, storage and unloading of plastic granulate, which it uses as raw material.

Why? The bulk packaging previously used did not meet the manufacturer's requirements. Jardin considered safety the greatest drawback of the old system.