The Situation

Damaged bulk bags were costing our prospective client well over six figures annually through product loss and customer claims. The client reached out to a consulting firm specializing in packaging. This firm in turn brought Bulk Lift in as a category expert. Our task was to supply an FIBC for personal care products that would eliminate damage and product loss while allowing easier use for the operations team.

To tackle this project Bulk Lift evaluated the entire process from fill to discharge. Taking into account and evaluating all the factors, fill method, discharge sequence, transfer points and transport methods, all the way down to the pallet utilized in tandem with the Bulk Bag.

During this evaluation, Bulk Lift noted the client had difficulty filling and discharging which was contributing to the stress on the bag, leading to damage. At the same time Bulk Lift evaluated the outbound shipment method to assess for contributing factors and explore potential gains we could further realize with the project.

Our methodology, where the Bulk Bag is part of a larger puzzle, allowed for a full life cycle assessment of the Bulk Bag and a root cause identification of why the prospective client had such a high cost of quality.

Our Solution

Looking at the full scope of the project, and piecing together all factors, Bulk Lift was able to develop a solution having the following positive impacts:

Elimination of Damage Through:

1. Full redesign of the Bulk Bag converting from a Baffled FIBC to a Stack-Pac M
2. Increased stability mitigating leaning
3. Elimination of pallet overhang Unitary Liner design eliminating stress points on the protective liner
4. Good Manufacturing Practices and design standards that eliminate abrasion points for the protective liner.

Operational Optimization:

1. Communicated best practices allowing for consistent and hassle free filling
2. Implemented a new container layout increasing the number of bags shipped on a single container
3. Reduced discharge time (was 90 minutes, now 15 minutes)
4. Reduced dunnage requirements and optimized container pack out process saving time