Smurfit Kappa creates rust-proof packaging for NSK

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NSK is a manufacturer of industrial machinery bearings, precision machinery and automotive components with manufacturing plants around the globe. The company supplies a number of leading car manufacturers, which means that NSK customers expect excellent service, all the way down to the smallest detail to ensure an efficient shipping process.

Due to an increase in lead times, NSK’s Peterlee plant decided that something needed to change – and so turned to Smurfit Kappa in Chesterfield for some assistance.

Smurfit Kappa had previously been working with the company, laboriously sampling packaging formats one by one. The global situation surrounding Covid-19 added urgency and products that were previously thought to be sound came under scrutiny. 

The challenge

Because many of NSK’s products are shipped overseas by boat, most of its packaging has a particular coating on the board – Paraten - which is a rust prohibitor. The global supply difficulties got the Smurfit Kappa Chesterfield team in an innovative mood; and they were ready to tackle any dilemma. So, they suggested a solution to the Paraten problem, experimenting with a volatile corrosion inhibitor (VCI) called Vaportech. 

Vaportech has several advantages over the alternatives. First, it’s easy to apply, essentially being printed straight onto the corrugated board in Chesterfield. This reduces lead times and allows Smurfit Kappa to supply NSK with its packaging in a quick turnaround period.

Furthermore, it is claimed to be eco-friendly, creating no waste through the printing process and being also water soluble, safe for the environment and entirely recyclable. 

Using Vaportech means Smurfit Kappa can craft the packaging from beginning to end in Chesterfield, with total control of the production process. This can also help in reducing both lead times and enables the Smurfit Kappa team to produce exactly as much, or as little as required.

As a final bonus benefit, Vaportech is bought in the UK – and cheaper to produce than the board containing Paraten. 

NSK quickly agreed to trial Vaportech. The result was packaging that could withstand even the roughest of seas and increased trust from NSK in Smurfit Kappa’s capabilities.

Working together

Smurfit Kappa Chesterfield recognised the potential to innovate with NSK. It knew it had to be creative and strategic in its approach, as supply chains across the UK were affecting Smurfit Kappa too. 

Working entirely in-house, Smurfit Kappa Chesterfield sourced, printed, die-cut, assembled and delivered its first prototype for NSK within two weeks. This quick thinking – and even faster turnaround – won the NSK team over and NSK tasked Smurfit Kappa with redesigning around 80% of its corrugated lines.

Trouble at sea

It wasn’t all smooth sailing for NSK. Although its main packaging had been dealt with, it was still facing delays; this time in the wooden shipping components of its shipping process, like pallets. 

Once again, Smurfit Kappa had a solution. The company suggested using Hexacomb with corrugated posts. Hexacomb is a paper-based alternative to materials like wood, offering strength and lightness. It’s based on the structure of honeycomb, which effectively absorbs shock and provides cushioning for products in transit. 

It’s rigid, so it can support heavy materials. It also stabilises loads, reducing or even eliminating product shift. And because it’s paper-based, it’s 100% recyclable, made from FSC-certified paper.

Working collaboratively, Smurfit Kappa Chesterfield and NSK have improved the packaging offering by leaps and bounds. On top of that, Smurfit Kappa is always looking to improve; the team at Chesterfield is currently looking into other ways to help NSK reduce lead times further. 

“Over the coming few years, we hope to work closely with NSK to optimise their packaging fully and continue this productive working relationship.” Mike Broad, Sales Manager at Smurfit Kappa Chesterfield.

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