Universal Solution for Radiator Shipments
The radiator industry faces unique packaging challenges due to; weight, shape, and fragility in horizontal and upright orientation. Traditional packaging methods; EPS, timber frames, and oversized cartons often lead to damage in transit, increased packaging costs and environmental waste.
The Challenge
A UK leading radiator manufacturer approached GAIA to develop a universal, single-use packaging solution that could standardise protection across their radiator range.
· Protect multiple radiator types and sizes (horizontal and upright) using a universal design.
· Develop robust corner and edge protection (high damage rates) to prevent dents, scratches, and paint damage during handling, stacking and shipment.
· Be stored and transported vertically and horizontally.
· Remain cost-effective, recyclable, and easy to pack on packaging lines.
Our Solution
GAIA’s AIR|TUBE™ + Reinforced Carton
GAIA introduced a dual solution combining the benefits of the inflatable AIR|TUBE™ cushions with heavy-duty reinforced cartons:
AIR|TUBE™ Protection
· Inflatable air tubes wrap around radiator corners and edges, forming a cushioning barrier that absorbs shocks and vibrations.
· Universal sizing accommodates different radiator dimensions without bespoke tooling.
· Supplied flat-packed, inflated at point of use, minimising storage and handling.
· Automated inflation offers on- demand supply on the packaging line.
Reinforced Cartons
· Designed with double-wall board grade and strategic reinforcement to withstand compression and stacking pressures.
· Cartons allow radiators to be stored and shipped vertically or horizontally
· Standard FEFCO designs adapted for universal pack-out.
Results & Impact
· Damage reduction: transit damage rates dropped from 12–15% to under 2%.
· SKU consolidation: Over 12 bespoke packaging formats replaced with a single universal AIR|TUBE™ solution.
· Operational efficiency: Faster pack-out times due to simplified carton loading and automated inflation process.
· Sustainability: 100% recyclable using over 4000+ Supermarket / Retail outlets participating in the UK governments ‘Recycle Now’ initiative. Eliminating EPS and wood packaging waste.
· Stackability: Reinforced cartons allowed safe palletisation and multiple stacking layers without crushing.
Ready to solve your packaging challenges?
Let's discuss how we can create a custom solution for your specific needs.
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