Case Study: Packaging solution for lorry headlamp surrounds

KSK coats headlamp surrounds for commercial vehicles – exceptionally large, flawless, delicate components. They must reach the manufacturer’s production line without damage and at optimised cost. Customers increasingly no longer handle packaging development for coated parts themselves, instead entrusting it to KSK as an integral part of the value chain.

• Exceptionally large components with delicate coated surfaces
• Damage-free transport over long distances
• Optimal use of transport space to optimise costs
• Smooth assembly on the customer’s production line
• Avoiding any contact with coated surfaces during transport and handling

In collaboration with specialist packaging manufacturers, KSK developed a comprehensive packaging system that ensures both flawless, cost-optimised deliveries to the plant and smooth assembly on the production line. Movement within the lorry during transport is prevented by specified, optimally tailored external dimensions (1000 × 1200 mm). The packaging space is utilised to the maximum with three component layers per packaging unit and three packaging units stacked on top of one another. Securing the parts without surface contact ensures that the coated component surfaces have no direct contact with packaging material – eliminating the need for additional costly transport protection solutions. Packaging the add-on parts in sets enables flexible handling directly at the production line.

• Specified external dimensions of 1000 × 1200 mm for optimal lorry utilisation
• Three component layers per unit, with three units stacked in the transport rack
• Coated surfaces secured without contact
• Arranged in sets to match the customer’s assembly process
• Packaging development integrated into the overall KSK process