Use case scenario

A logistics company specializing in warehousing and distribution needed to optimize its secondary packaging to prevent deformation and collapse when boxes were stacked in storage facilities and shipping containers.

Challenges faced

• Load Capacity Variations:Boxes experienced inconsistent loading conditions due to stacking heights and external pressure changes.
• Material Efficiency:The company sought to minimize packaging costs while maintaining structural integrity.
• Environmental Impact:Humidity and temperature variations affected box strength over time.

Simulation Process

1. Box Design Evaluation:
• Different corrugated board types were analyzed for their compression strength.
• Flute size, board thickness, and adhesive strength were optimized.
2. Top-Load Testing:
• A virtual simulation using Finite Element Analysis (FEA) was conducted to predict stress distribution.
• Real-world load conditions, including uniform and point loading scenarios, were applied.
3. Optimization Strategies:
• Reinforced corner structures and improved flap designs enhanced durability.
• Strategic perforations helped maintain ventilation while preserving strength.
• Cost-effective material substitutions were tested to maintain sustainability.

Outcomes

• Improved Load Resistance:The optimized design increased top-load capacity by 25% without additional material costs.
• Reduced Product Damage:Simulation-driven modifications led to a significant decrease in damaged goods during transportation.
• Sustainability Gains:The revised box design used eco-friendly materials and contributed to reduced carbon footprint.

Conclusion

Top-load simulations for corrugated secondary boxes enable manufacturers and logistics providers to enhance packaging durability while optimizing costs. By leveraging simulation data, companies can ensure better product protection, reduce waste, and improve operational efficiency.