How to pack automotive parts – 11 vital considerations

The fragility of your car parts is another factor that dictates the optimal packaging for your business.

You may need cushioning and inserts to reduce damage from handling within the supply chain, even for more durable items that may not require such a high degree of protection.

The packaging required for shipping high-value items like infotainment units or gearboxes should differ from those used for less expensive plastic trims or ancillary components.

This approach ensures that valuable items do not suffer costly damage in transit while keeping packaging costs to a minimum for other parts.

Evaluating the ease and speed of packing and unpacking your products is essential.

Does your car parts packaging involve many secondary materials like bags, inserts, or films?

Is it straightforward to pack multiple smaller components into a single outer container?

Additionally, are there any extra steps that packing teams must undertake that could potentially affect production speed and efficiency?

It’s prudent to consider how your items are managed throughout the supply chain.

For instance, are there numerous touchpoints where mishandling could occur? Does the packaging need to appear presentable upon reaching its final destination, such as for aftermarket parts or retail items?

In addition to considering handling practices, it’s crucial to contemplate the modes of transportation and potential environmental conditions your car parts packaging might face. For instance, will it be exposed to outdoor elements or have the risk of getting wet?

One of the most crucial decisions when shipping car parts is choosing between expendable and returnable transit packaging. So, how do you determine which option is best for your business?

Generally, the longer the distances in the logistics chain, the less feasible returnable packaging becomes. Most returnable automotive packaging is utilised within shorter loops, often with fixed arrival and distribution points.

There might be scenarios where you lack reliable return transport, the parts are intended for direct use by the end consumer (making return impossible), or it’s not cost-effective to return empty containers to your warehouse or manufacturing facility.

Additionally, it’s essential to consider the preferences of different manufacturing plants or customers. Some may lack the infrastructure to dispose of large amounts of single-use packaging and only accept products in returnable packaging, while others might specifically request expendable packaging.

With technological advancements, many features in new vehicles depend on electronics and microchips. Systems like telematics, navigation, driver assistance, and even infotainment units use increasingly sophisticated technologies.

However, these parts and components are vulnerable to a distinct type of damage known as electrostatic discharge (ESD).

ESD refers to the exchange of an electrical charge between two objects. While this phenomenon occurs naturally, the heat produced during this process can inflict substantial damage to microchips and electronic components.

Because of this, various anti-static and conductive packaging solutions are essential in the automotive industry. Popular options, such as Corstat, create a “Faraday cage” effect that directs any static electricity around the exterior of the packaging.

A volatile corrosion inhibitor (VCI) is a material that protects metals from corrosion (i.e. rust). Vehicles use a considerable amount of metal components, so shipping these over long distances has the potential for this type of damage to occur.

Numerous VCI papers and bags are available to pack components, while others may be coated in grease or similar substances to protect them during shipping. However, all these add another process to packing and unpacking operations.

An alternative is to coat your packaging with a VCI material, which can provide equivalent protection.

It is essential to consider protecting surface finishes on painted, polished, or decorative components (such as dashboard trims, door cards, switchgear, etc.).

Typically, manufacturers specify that their tote inserts and dividers should use specialist materials that reduce surface scuffs and blemishes.

Less commonly recognised is the fact that cardboard can be unexpectedly abrasive. However, there are coatings available for corrugated boxes that can help mitigate this issue.

A new challenge for automotive manufacturers and parts suppliers involves lithium batteries. Commonly found in electric vehicles, the UN classified li-on batteries as hazardous materials. This classification mandates specialised packaging that is compliant with specific regulations (UN3480) for shipping.

Potential solutions include reusable aluminium cases equipped with specialised inserts designed to contain fires in the event of battery failure or malfunction during transport.

Finally, what is your packaging’s environmental impact?

Does it enable you to optimise transport efficiency, or are you shipping a significant amount of empty space? Can single-use packaging be readily recycled by your customers or the end user? Or would returnable packaging be the most appropriate choice?

With most businesses placing significant importance on the sustainability of their operations, plus considerations regarding new legislation, ensuring your packaging minimises environmental impact is crucial.

Whether you manage packaging at an OEM, tier 1, tier 2, or tier 3 supplier, how you pack your automotive parts is obviously vital.

But so is your automotive packaging and, by extension, your packaging supplier.

At GWP, we have more than 30 years of experience supplying commercially successful automotive packaging to businesses of all sizes. We can also offer a full design service, manufacture your packaging at our UK manufacturing facility, and provide the full range of returnable and single-trip packaging options.

Contact us today for expert advice and assistance in finding the best packaging solution for your business.