Catalytic Converter eCommerce Packaging

A ceramic cylinder with a fine mesh inside.
An ArtiosCAD 3D render of the corrugated inserts and the converters.
A cross section of the corrugated and foam inserts.
A top-down view of the package featuring the Ranpak Geami paper.
A white box with dimensions overlaid on it.
A white box with a top load on a vibration table.

Team Members:

  • Meredith Brooks
  • Jordan Evans
  • Ben McMurray
  • Jack Thompson
  • Shane Yuhasse

Objective:

  • To package eight ceramic catalytic converters for eCommerce according to ISTA 6A standards.

Solution:

  • A C-flute Center Special Slotted container with three foam cushions to protect the converters from shocks.
  • Two C-flute inserts and Ranpak Geami paper hold the converters in place.

Challenges:

  • Adequately protecting the ceramic cylinders while minimizing material use.
  • Finding a recyclable alternative to conventional foam cushions.
  • Navigating in-person lab restrictions due to COVID.

Successes:

  • Minimized shipper size by stacking the converters in two layers of four.
  • Absorbed the shock from drops with the combination of corrugated inserts and foam cushions.
  • Reduced physical waste by 41% in comparison to conventional packaging solutions.

Potential Improvements:

  • Use an RSC instead of a Center Special Slotted container to further reduce material use.
  • Eliminate the use of Ranpak Geami paper.
  • Use thicker cushions with circular cutouts to eliminate the use of corrugated inserts.