Challenge: A major electronics supplier shipping high‑value components between plants across India faced chronic issues: fragile parts were often damaged due to inadequate single‑use packaging, and missing shipments delayed production. The company maintained large inventories of various box sizes, which occupied warehouse space and tied up capital. Tracking each shipment was largely manual, resulting in poor visibility and frequent loss of containers.
Solution: ULS Pooling designed custom returnable crates with precision‑engineered dunnage and anti‑static materials to safeguard printed circuit boards and sensors. The collapsible crates provided multi‑layer dunnage options so that multiple components could be securely stored and accessed Because the crates fold down to a fraction of their original size when empty, they save storage space in the supplier’s warehouse and reduce return‑transport costs. ULS included temperature and humidity sensors in the packaging; IoT tags continuously collected condition and location data and transmitted them to ULS’s platform for real‑time monitoring. Geofencing alerts triggered immediate notifications if containers deviated from planned routes, mitigating theft and loss.
ULS’s service included washing, inspection and maintenance of all returnable crates, ensuring that packaging remained clean and free of contaminants. The supplier paid only for the period of use, freeing capital and simplifying budgeting.
Results: The switch to reusable packaging delivered long‑term cost savings; although returnable containers require higher initial investment, the cost per shipment drops with each reuse. The durable, protective design minimized product damage and loss, reducing rework and scrap costs. Real‑time tracking improved operational efficiency: accurate asset data prevented delays and ensured that crates were available when needed, which is critical for meeting tight production schedules. Condition monitoring allowed the supplier to identify potential issues, like elevated temperatures or shocks, and take corrective actions before products were damaged.
Adopting reusable packaging and pooling also enhanced sustainability. By keeping containers in circulation instead of discarding them, the supplier reduced waste and resource consumption; reusable packaging minimizes the demand for new materials, decreasing energy usage and greenhouse‑gas emissions. The standardized crates optimized warehouse layout and simplified automation, while IoT analytics provided insights that improved resource allocation.
