Customer Success Story: Smarter Export Packaging for Heavy-Duty Electronics
Industry: Heavy Engineering & Electronics
Solution: Advanced Machinery Packaging for Air Export
Challenge
A leading manufacturer of heavy electronic equipment faced frequent product damages during air exports.
Their existing packaging design – a wooden box fixed with nuts and bolts on a wooden pallet – was bulky, heavy and difficult to handle.
During the Diwali season, their product demand spiked by 12 times, creating additional challenges:
- Delays in packaging due to limited vendor capacity
- Increased air freight costs from heavy packaging
- Inefficient packing process consuming excessive manpower and time
TSW’s Rapid Response
Understanding the urgency, TSW Industrial Solutions Pvt. Ltd. took immediate action.
Our team completed the entire process from design, prototyping and costing to pilot order execution – within just 3 days.
The goal was clear:
Create a lightweight, durable and export-compliant packaging solution that could protect sensitive electronic components while optimizing logistics.
Our Engineered Solution
We developed a Heavy-Duty Corrugated Box mounted on a plywood pallet, integrating multiple layers of protection:
- VCI Film & Desiccants – To prevent rust and corrosion
- EPE Foam Cushioning – For electrical insulation and shock absorption
- LDPE Bag & Wrapping – For moisture and dust resistance
- High-Strength Strapping and Edge board – For load stability during handling and transit.
This innovative design ensured product safety without the excess weight and cost of traditional wooden boxes.
Key Features
- Lightweight yet highly protective
- Durable and sustainable construction
- Easy to pack and unpack
- Branding options for export visibility
- Enhanced product safety during handling and shipping
Results & Benefits
The new solution delivered measurable improvements across performance, cost, and operations:
| Parameter | Before (Wooden Box) | After (TSW Solution) |
|---|---|---|
Export Cost |
High due to packaging weight |
Reduced by 4x |
Storage Space |
Bulky materials |
10x more storage efficiency |
Packing Efficiency |
4 manpower for 1 box in 2 hrs |
2 manpower pack 5 boxes/hr |
Supply Chain |
Dependent on limited vendor |
Streamlined and scalable |
Overall Impact
- 25% reduction in total product cost
- Zero damage incidents during export
- Improved speed and efficiency throughout the supply chain
Conclusion
By switching from traditional wooden packaging to TSW’s heavy-duty corrugated export solution, the customer achieved a perfect balance of protection, sustainability and efficiency.
This project highlights TSW’s ability to respond quickly, design intelligently and deliver measurable value – even during high-demand seasons.