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Projects

Recent work, from concept to series

Eleven projects from our own files. Customers are anonymized, every card shows where the project stands today, and we only state results that are documented. Happy to talk through the details on a call.

Automotive OEM · BeneluxIn series

One returnable tray system, four plants

A new e-transmission plant with many new employees and no packaging specialist in-house.

Twinsheet traysTestingVCI
Read the case
Challenge
Cleanliness issues, transport damage and slow handling, in a plant still building up its team.
Approach
Twinsheet trays and Euronorm boxes per part family, tested for dust ingress and condensation, with VCI bags for the hydraulic units.
Where it stands
In series since 2023 and now used at four plants of the group.
Automotive OEM · BeneluxTrial

Hydraulic units on a europallet

Layouts for hydraulic control units on a 1200 × 800 europallet, for the same e-transmission group.

EuropalletTrays and dividers
Read the case
Challenge
Dense, clean packaging for heavy cast units that fits the plant's handling and the europallet footprint.
Approach
Tray and divider layouts on 1200 × 800, with VCI protection, built and trialled at the plant.
Where it stands
Trialled at the plant in 2025.
Automotive OEM · BeneluxTrial

Repairing trays instead of replacing them

Damaged twinsheet trays coming back from the loop.

Damage analysisTray repair
Read the case
Challenge
Trays with broken corners and edges, and no clear view of where the damage happened.
Approach
Damage logged with photo sets, most of it traced to handling at the receiving plants, repair trials with a specialist, and reinforced corners in the next design.
Where it stands
Repair trials in October and December 2025; handling improvements on the agenda with the plants.
Machining supplier · NetherlandsCompleted

The rust didn't come from the packaging

Machined pump housings kept arriving with corrosion spots.

Root causeClimate test
Read the case
Challenge
Corrosion after storage and between process steps, despite VCI bags and desiccant.
Approach
A 14-day climate-chamber test to PV 1210, which simulates about 15 years of sea freight, comparing two protection systems on real parts.
Outcome
The test showed residues from the washing process caused the corrosion, not the packaging. The advice: fix the wash first, then choose the VCI and desiccant.
Machining supplier · NetherlandsConcept

From 40 to 140 parts per pallet

A bearing flange for a German machinery plant that took up too many storage places.

Pack densityCardboard
Read the case
Challenge
Only 40 parts per pallet in two layers, on a top-5 item for storage space.
Approach
A 7 × 4 cardboard divider (1,156 × 756 × 60 mm) that carries the layers above, five layers of 28 with interlayer sheets, and an assembly jig for fast insertion.
Where it stands
Quoted in October 2026; a five-layer test pallet must be approved before the first series order. The customer's own estimate: about €0.24 per part in transport and five storage places.
Turbocharger manufacturer · NetherlandsOngoing

A full packaging portfolio, ready for PPWR

Project lead for PPWR readiness since July 2026.

PPWRDoC review
Read the case
Challenge
A large packaging portfolio from many suppliers, and the PPWR milestone of 12 August 2026.
Approach
Packaging portfolio mapped, every European supplier asked for its Declaration of Conformity, a DoC register set up, and each incoming declaration scored with our DoC tool. EPR registration and formal sign-off through our compliance partner.
Where it stands
Ongoing, with on-call support for the customer's team.
Automotive OEM · ItalyTrial

KLT boxes and pooling for a new flow

Differential parts for a plant in Turin, in standard KLT boxes instead of dedicated packaging.

KLTPoolingPool size
Read the case
Challenge
A flow of about 600,000 parts a year, to be packed in standard boxes that can be rented rather than bought.
Approach
Inserts for standard KLT boxes (18 differential parts per box for the main part), a pool-size calculation for the whole flow, and rental proposals from pooling partners.
Where it stands
Field test at the plant in 2025.
Driveline manufacturer · Belgium → MexicoConcept

32 clutches per returnable pack, across the Atlantic

Clutches of 12.4 kg shipped to Mexico, about 15,000 a year, six weeks each way.

Sleeve packExport
Read the case
Challenge
A long sea loop where every empty pack is expensive, and parts that must not touch.
Approach
Three routes compared: europallet with honeycomb (22 per pack), PE-foam inlay (32 per pack, but over €500 per inlay), and the recommended sleeve pack of 1,220 × 1,150 × 545 mm with a PP divider: 2 layers × 16 = 32 parts, about 400 packs for the loop.
Where it stands
Proposal stage (September 2026); samples planned.
Truck gearbox supplier · RomaniaIn series

Compartments for truck gearbox gears

Lower-cost protective packaging for gears, to the truck maker's own box specification.

PP compartmentsSeparators
Read the case
Challenge
264 gears per box (24 per layer, 11 layers), with no contact between parts, at a lower price.
Approach
A 6 × 4 PP compartment (736 × 536 × 41 mm) with separators, followed in 2026 by PP sheets with recesses for two more gear types.
Where it stands
In series since 2024; new gear types added in 2026.
Truck component supplier · NetherlandsConcept

Wheel-hub trays for a robot line

The robot and sensors couldn't cope with the VCI liner in the current packaging.

AutomationReturnable trays
Read the case
Challenge
Parts had to be repacked by hand before the automated line, on a flow of 50,000 parts a year between Italy and the Netherlands.
Approach
Returnable trays of 1,185 × 785 mm for 6 hubs per layer, 2 layers per sleeve box, a VCI hood over 12 parts and a gripper that removes the empty trays. Pool sized at 1,314 trays and 660 sleeve boxes for a 35.5-day loop, with shock, vibration and condensation tests planned.
Where it stands
Design and pack specification ready (2025).
Own development · built in VietnamPrototype

A one-hand dispenser for desiccant and VCI pouches

A gravity-fed dispenser that hands out one to three pouches at a time at the packing station.

Product designSourcing
Read the case
Challenge
Hand out desiccant and VCI pouches quickly and cleanly at the packing station, one to three at a time, with one hand.
Approach
Our own design: 45 litres, a 30° anti-jam funnel, a spring-loaded one-hand flap with a 46 mm finger gap, polycarbonate windows and a powder-coated steel body. Built with a maker in Vietnam.
Where it stands
Samples and tooling ordered in spring 2026.
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