Retail•1 min read•Aug 28, 2025

AIR|TUBE & Foam/Carton Kits for White Goods

A major UK-based manufacturer and retailer of domestic white goods—including refrigerators, ovens, washing machines, and dishwashers—delivering products via retail and direct-to-consumer channels.

Client:White Goods Manufacturer & Retailer
Industry:Retail
Type:Product Implementation
AIR|TUBE & Foam/Carton Kits for White Goods

The Challenge

The client needed to improve protection of their white goods along their supply chain and  distribution channels. This involves shipments from hubs to retailers outlets and final mile to end users. Their key challenges included:

  • Transit Damage: Corners, fascias, and control panels were particularly vulnerable during loading, transport.
  • Excessive & Wasteful Foam: Legacy packaging relied on bulky, non-targeted foam inserts, clashing with sustainability goals and increasing material waste.
  • Inefficient Packing Process: Manual assembly slowed down production line throughput and created inconsistencies in pack quality.
  • Packing Efficiency: Multiple SKUs and non-uniform packaging process

Our Solution

1. AIR|SHIELD™ Integration

  • Inflatable AIR|TUBE™ chambers designed to protect sensitive zones (edges, doors, control panels)
  • Supplied flat and inflated on-demand - no tooling required
  • Eliminated excess foam usage in non-critical areas
  • Pneumatic (air) product offers greater In-Box Protection

2. Foam & Carton Kits

  • High-density foam bases made from fully recycled (PCW) PE for durable cushioning
  • Universal modular carton trays (FEFCO 0409) adaptable to multiple product types
  • Cartons designed to integrate AIR|TUBE™ seamlessly while maintaining load stability.

3. Pack Standardisation & Efficiency

  • SKU Rationalisation - 2 standard kits covering over 95% product range
  • Standardised / Uniform packaging of components and improved identification
  • Significantly improved assembly line speed and pack-out time

Results

KPIBeforeAfter SolutionImprovement
Transit Damage Rate
4.8%
0.7%
85%
pack Out Time/ Transaction
6 minutes
3.5 minutes
41%
Number of SKU's
14
22 (via modular kits)
57%
Pallet Space Used (Packaging Store)
10 Pallets
4 Pallets
60%
Recyclable Content (%)
40%
85%
112%

Results & Impact

GAIA delivered a hybrid packaging approach - combining AIR|TUBE™ inflatable protection with sustainable custom foam and carton kits

"The AIR|TUBE™ hybrid solution gave us targeted protection exactly where we needed it, while the foam/carton kits improved pack consistency. We’ve seen a major reduction in field damage claims and faster packing on our assembly stations."
Logistics Manager
UK White Goods Manufacturer
automotiveprotectionwindscreens

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