Single Use Universal Solution - Internal Doors
The internal door industry has long relied upon traditional packaging e.g. shrink wrap to ship their products safely. Unfortunately, these traditional methods often fail to provide adequate protection, reusability options, whilst limiting logistics and palletisation efficiencies.
The Challenge
Recognising these shortcomings and challenges, we set out to design a reusable single-use packaging solution that accommodates all internal door configurations, ensuring safe transit and handling in vertical and horizontal orientations, and supports pallet stacking with minimal product damage.
Our Solution
Our proposed single-use system is based on a modular approach:
- Universal Foam Supports:
A set of four custom-fabricated U-profile High Density foam supports, manufactured in a hockey-stick style configuration, secure and cushion the internal door during transit. - Optional Laminated Protective Faces:
Where higher-surface finishes require additional protection, laminated faces can be applied – to be discussed and tailored to specific client needs.
Design Benefits
- One Design: fits standard and non-standard internal door sizes without the need for multiple packaging SKUs.
- Flexibility: enables safe vertical or horizontal storage in vehicles and warehouse racking.
- Efficiency: supports pallet stacking of up to 4–5 units per pallet space, maximising load efficiency while ensuring structural safety.
- Sustainability: the high density foam
Reusable Packaging Solution
In parallel, a reusable system is being developed with an expected lifecycle of 35–50 uses (to be tested). This option will provide:
- Reduced total cost of ownership over time.
- Significant reduction in packaging waste streams.
Consistent protection levels across repeated supply chain cycles.
Results & Impact
By combining single-use flexibility with the potential for reusability, this solution offers a future-proof approach for door manufacturers and distributors.
The project is now moving into prototype testing, including trials for:
- Compression testing for pallet stacking.
- Drop and transit simulations to validate foam protection performance.
- Workflow efficiency checks for ease of assembly and removal at point of use.
Once trials are complete, the solution will be scalable across production and distribution networks, with potential adaptation for external door ranges and other flat-packed products.
Ready to solve your packaging challenges?
Let's discuss how we can create a custom solution for your specific needs.
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