Baxi Changes From Cardboard to EPS Packaging

This January, Styropack UK celebrated the completion and implementation of a 9-month project that saw Baxi Heating UK Ltd. change its entire range of High Efficiency Boiler packaging from corrugated cardboard to EPS (expanded polystyrene) packaging.

Baxi Heating UK Ltd. drove the move to EPS in response to requests from its customer base of installers. The changeover also yielded some additional benefits; Styropack designed a groundbreaking package for the Baxi range of combination boilers. It improved the functionality of the pack, as well as providing better protection and, a patent application for the design is currently being processed.

Steve Pilkington, Group Development Manager explains: "The pack has a 'break-off' back. Installers can snap off the back of the EPS pack, lift the boiler onto the wall using handles that are moulded into the EPS by design, install it, and then remove the rest of the pack. The great thing is that it doesn't hurt the installers' hands. This simply could not be done with a cardboard pack."

The result is not just a pack - it is a handling system. It assists the installation process and provides the outstanding cushioning and protection that EPS is famous for. This robust, reliable protection is important as Baxi Heating UK Ltd. boilers are faced with a difficult logistics chain.

Steve Pilkington explains: "Our boilers may be warehoused two or three times during the journey from us to a customer's home. EPS does not deteriorate in damp, cold warehousing, so its excellent protection and compression performance remains stable. That means the boilers can be safely stacked and moved around the warehouse without being damaged."

One of the restrictions placed on Styropack was to design packaging that could be used on the existing manufacturing line. This kept the changeover costs to a minimum, although the new packaging has, of course, changed the packing process at Baxi.

Steve Pilkington explains the new set up: "We have introduced a JIT process for the new packaging which means that we do not hold too much stock on-site. The EPS packaging is fed to the lines on a total flow basis, and where previously cardboard flat-pack pieces had to be folded into shape, the EPS is ready to use and hence will save labour on the assembly lines. That has reduced our labour time, we no longer have to unfold and construct the cardboard packaging, and so the packing process is quicker."

For Styropack's Head Designer, Brent Lofthouse, this has been a dream job: "It has been great to design a comprehensive packaging system like this. I worked closely with the client throughout the design process, modifying the plans to meet their requirements and adapting the tool. Baxi works to an incredibly high standard and I have enjoyed every minute of working with them."

Lofthouse designed universal packaging systems that could be used on several similar models using the same packs. The end result is five different Combination boilers packed in a universal pack, six different Heat Only boilers in a universal pack and three different Suprima boilers packed in a universal pack.

For Styropack, the total value of the job in 2006 was £675,000. But, that is not all the work meant to the company, Richard Lee, Sales Director, Styropack UK concludes: "It has been great to work on a project of this scale and to design a completely new concept that can be patented."