Shipping LED TV’s (32”–85”) via courier networks
Transporting TVs remains a critical challenge for manufacturers, distributors, and aftersales service providers due to their fragility, size variations, and costly components.
The Challenge
Traditional polystyrene end caps or foam blocks often fail to meet damage targets, CSR/ESG goals, occupy significant warehouse space, and require multiple SKUs to cover different screen sizes.
To address these challenges, GAIA developed an AIR|SHIELD™ packaging solution that protects the entire TV range from 32” to 85”. Reducing transit damage rates, return / repair / BER costs whilst maximising logistics efficiency.
Our Solution
1. AIR|SHIELD™ End Caps
· Manual & Automated Inflated options – giving you the most appropriate option for your production flow.
· Inflatable end caps conform to the edges and corners of TVs, creating a snug fit that protects against drops, vibration, and compression forces.
· The pneumatic (air) characteristics of the packaging material dissipates the energy produced due to movement and impact during transit better than traditional alternatives
· Standardised packaging and reduction in carton and packaging material SKU’s
2. Bespoke Outer Carton
· Heavy-duty corrugated carton designed for single, multiple legs or bulk shipments.
· Compatible with warranty and non-warranty repair returns and new or refurbished product distribution.
· Optimised for courier and palletised networks, reducing over-packing and freight costs.
3. Universal Fit & Scalability
· One solution covers all TV sizes between 32” and 85”.
· Removes the need for multiple carton and foam SKUs.
· Ideal for forward logistics (new products) and reverse logistics (repair/refurbished markets).
Results & Impact
· Damage rates reduced to well below industry average (<1%).
o Significantly lowers screen cracking and edge chipping incidents during transit.
· Sustainability: Replaces non-recyclable EPS foams with recyclable air-based protection.
· Cost Efficiency:
o Universal design reduces SKU complexity.
o Rackable flat storage of uninflated end caps saves up to 80% warehouse space.
· Scalable: Manual option for aftersales and low-volume runs, automated system for large-scale production.
· Improved Packaging Efficiency – low storage footprint, automation, single SKU solution and carton reduction produced over 50% packaging efficiency.
Ready to solve your packaging challenges?
Let's discuss how we can create a custom solution for your specific needs.
Related Case Studies
Universal Packaging Solution for 1U & 2U Server Units
A leading IT hardware distributor specialising in 1U and 2U rack-mounted server units sought a scalable, protective packaging solution for their refurbishment servers for shipping via challenging courier networks (parcels) and palletised movements.
Protecting Computers, Accessories & Components
Several distributor of Computer Systems and High-Value Electronics (UK-Based Distribution Hub) encounter high rates of cosmetic damage and product failures causes during the transport of finished desktop units, laptops, AIO’s, monitors, motherboards, and sensitive peripheral components.
Universal Network Switch Solutions
Network switches are critical IT infrastructure components, often used in data centres, enterprise networks, and telecom environments.