Since we first introduced Eco Flex™ two years ago it has become a customer favorite for those who package a variety of products but not necessarily in large volume. Let’s face it, if you ship out a lot of anything, it is relatively easy to justify the expensive tooling required for custom corrugated die cut inserts or custom molded pulp trays. However, if your volume is measured in hundreds or thousands, rather than millions or if your products differ in size or shape, affordable packaging solutions, especially GREEN packaging solutions, can be difficult to find.

An easy solution for complicated packaging problems

Most people may not fully understand the different properties required for basic void fill compared to a blocking and bracing interior packaging application; or they may have little interest in the technical explanation of how shock transfers to a product when a shipping box is dropped. However, they are probably keenly aware of their damage rate and how it can negatively impact their business. Eco Flex™ is a unique STOCK molded pulp product that is versatile and affordable, even when purchased in small quantities. Eco Flex™:

1. Immobilizes the product within the box being shipped to makes sure it is not damaged from within.
2. Cushions it to prevent damage from the outside
3. Absorbs shock so it does not transfer to the product when the shipping box is dropped

A Green and Versatile Packaging Solution

Molded pulp is among the greenest packaging products available because it consists of only post consumer paper based waste. Unlike most molded pulp, the unusual (waffle) configuration is highly versatile since it can be flexible, easily cut, folded or even rolled into a tube shape to conform to virtually any product size or shape. The photos included in this post are only a small example of how Eco Flex™  can be used and customers are creating new uses, almost daily.

When is Eco Flex the product of choice?

Every situation deserves an application review but we usually suggest Eco Flex® when the product is expensive and heavy, as well as susceptible to damage in shipment. Product examples range from glass jars and bottles to expensive electronic equipment.

Providing a property, for example – shock absorption, could possibly be accomplished with a different packaging product but might require a lot more to achieve the same level of protection. In most applications, Eco Flex™ can be a low cost solution that often results in lower material cost, lower labor cost, and even a smaller, lighter box, which reduces shipping costs.

Again, every application is different so let us guide you toward the best solution for your specific purpose. Remember that Eco Flex™ is available in a low, one case minimum, so when in doubt, try a case from our web store and see how you could benefit from its versatility.

Please contact us at Salazar Packaging and Globe Guard Products if you have any questions or would like to see a sample of Eco Flex™.

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http://blog.salazarpackaging.com/sustainable-products/eco-flex-solves-multiple-tough-packaging-applications/

http://blog.salazarpackaging.com/sustainable-products/response-of-the-pulp-people-%e2%80%93-a-sustainable-packaging-adventure/

http://blog.salazarpackaging.com/sustainable-products/new-green-packaging-product-%e2%80%93-globe-guard-eco-flex-molded-pulp/

CELL PHONE MAILER WITH BUILT-IN INSERT

Corrugated inserts to hold and protect a product within a mailer shipping box are usually a great packaging solution. In most cases, they reduce or eliminate the need for additional protective packaging products such as foam, paper or bubble packaging, and the labor required to use and apply those ancillary packaging materials.

When is a “built-in” insert advantageous?            

In some situations, it is wiser to create a mailer box and use separate inserts for different size or shape products. Being able to stock one box and only have to swap out the inserts can be the most convenient and economical way to go.

However, in many other circumstances, when the mailer box is going to be used only for one product size and shape, there are numerous advantages to using a mailer with a built-in insert. These benefits may include:

• Lower packaging cost – typically a built-in insert results in lower cost because there is less waste and scrap.
• Reduced procurement costs – both necessary components are ordered, shipped and delivered together resulting in overall savings.
• Minimized storage and handling costs – valuable warehouse and pack station space is saved by not requiring multiple packaging components.

Simple Packaging Sustainability

There are many areas in packaging that are quite complicated and require a lot of data and analysis. This is sustainability simplified – anything that uses less packaging materials and costs less energy to produce, ship and store is good and green.

To make our die-cut mailer and insert designs a little greener, we use only our Globe Guard® 100% recycled content corrugated board. We can customize the finish and print them with custom graphics but we always make sure we maintain our ability to also make it 100% recyclable, repulpable and even biodegradable.

An Application Analysis

This is always the first step in the process for us and helps us to design correctly for the application. After all, what is the point of buying custom packaging if the “fit” isn’t perfect and the particular application requirements are not satisfied? For example, on the cell phone box shown in the photograph above, the goals were to be able to use a standard UPS or FedEx label, to minimize or eliminate interior protective packaging and to provide a perimeter “crush zone” to protect the product.

Contact Salazar Packaging to discuss your packaging challenges, and we can assure you we will be able to create a greener and lower cost package design than you might expect.

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The Difference Between Partitions and Molded Pulp for Protective Packaging Applications

• The increased focus on overall packaging reduction and the use of greener packaging materials
• The “concept to store shelf process” is faster, easier, and more affordable than ever.
• The image quality is better than ever, providing the shelf appeal companies are demanding.
• The unprecedented growth of multi-packs for price clubs and large volume retailers

For some customers and suppliers of packaging materials, printed shrink film can be intimidating because they don’t realize how easy and inexpensive it is when compared to other branding and unitizing options. Here are a few of the most common questions we are asked:

How can shrink film made of plastic be considered “green?”

If you agree that reduction of packaging by weight and volume is important, there are few materials able to help accomplish that like thin gauge, polyolefin shrink film. Not only are most of our formulations recyclable, but also in the vast majority of applications they are replacing a variety of other expensive packaging such as trays, pads, fold-over cards and labels. Take a close look at how much packaging you end up with after you take apart a typical multi-pack and you’ll see how much of it can be replaced by a lightweight, well designed shrink film over wrap. In many cases, shrink film can reduce packaging by as much as 60% or more.

Doesn’t copy on shrink film distort as it shrinks?

If the copy is not laid out correctly, most definitely yes. This is where experience is invaluable, because there are many ways to minimize or eliminate copy distortion including the type of copy and the location. By reviewing your product, application and even your shrink equipment, our experienced people can help you develop artwork that will result in the best possible appearance for maximum shelf appeal.

What is the difference between random repeat and registered print?

Registered print results in one image per package with the help of an eye mark that is designed into the printed copy, and the wrapper reads for perfect and consistent image placement. Random repeat printing has an image that is repeated in a seemingly ”random” pattern but is actually printed in a consistent pattern across part or all of the film web. Typical random repeat prints might feature a web address, logo or other information you wish to make “impossible to miss.” This type of print is often used for tamper evidency or security purposes.

Isn’t the process long and expensive?

Situations differ, but in most cases the process takes weeks rather than months. Once the art is approved and printing plates are made, lead times can be as short as a few weeks for re-orders. Most of the design time, including mock-ups, is done at our expense, and the one-time printing plate cost to you is also minimized.

What is NOT a good application for printed shrink film?

Simply put, immediate, one-time short runs. If you have to run a few thousand pieces in two weeks, your needs are probably best served by a variety of other packaging options. However, if you have a medium- or large-volume application requiring a corrugated or paper board insert or tray, or if the application will require multiple labels, printed shrink film can probably deliver substantial and greener results.

When in doubt, please contact Salazar Packaging. We will be glad to review your possible application, and if there is a better alternative we will not hesitate to suggest it to you. If, however, clear or printed shrink film is indeed the best, lowest-cost and perhaps the most eco-friendly option, we will help make the process as trouble free a possible.

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Branding and Messaging Goes Way Beyond Sustainability

Branding Made Easy With Green Packaging Group Teamwork

Spend a few minutes on their web site and you’ll understand why this organization is so concerned about the health and well being of this endangered species. This is an organization that deserves and needs our support, and I encourage you to visit their site to “like” them on Facebook and follow them on Twitter.

CUSTOM-PRINTED TAPE AND END LOAD FOL BOX

Your Packaging Can Be Your Ad

We tend to think of a package in terms of the customer it is being shipped to and we have learned how important that initial contact is. It makes a memorable impression, and branded packaging can help determine if that is a positive or a negative one. That package arrives at its destination, and it is a great opportunity to send or reinforce a message of your choice, whether it is as simple as showing off your logo, or perhaps communicating an important eco message about your company or your product.

What we tend to forget is that your package also makes contact with countless people and is seen at sorting and distribution centers and by people loading and unloading freight. Many people see it beyond the driver who picks it up or delivers it. Each one is a point of contact and an opportunity to capture attention.

Custom-Printed Boxes and Tape

The nice people at Sea Otters.com realize each one of those points of contact is an opportunity to gain attention and support for their mission. So they developed adorable, incredibly eye-catching artwork, and we printed it on to our popular and eco-friendly water-activated paper tape. They considered printing their shipping boxes, but with the box sizes and quantities uncertain at this stage, custom-printed tape was the best and most economical way for them to go.

On the box, however, to drive home their equal concern for the environment in general, they decided to include a brief eco message letting everyone know the box is constructed of 100% recycled content board, as are all of our Globe Guard® boxes.

Regardless of the message you want to drive home, we can help you accomplish it with the variety of custom-printed, eco-friendly packaging we offer. Please contact Salazar packaging for a no-cost, no-obligation review of your needs.

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CHARLIE CHIANG OF REGULATION TACTICAL

What does a Marine do after three combat tours? If that Marine is Charlie Chiang, he comes home and manufactures hardware designed to make life easier and perhaps a little safer for his fellow soldiers serving overseas, as well as for domestic law enforcement personnel.

Minimizing Pain for Our Troops 

Charlie is the founder and president of Regulation Tactical, a new startup company with great potential and an even greater purpose. During his service time in the Marines, Charlie personally suffered and witnessed the excruciating pain caused by the heavy equipment soldiers often have to carry. So, after discharge, he created his first product, the L.L.B., which is an acronym for “Load Bearing Brackets.”

Essentially, the weight of the gear being carried by our troops in the field is re-distributed, reducing pain and strain on the back, neck and shoulders. The idea is terrific, and gratefully it is a product that most of us will never have to use, but we are all glad someone like Charlie has the experience to make it for our men and women in uniform.

REGULATION TACTICAL BOX WITH WATER-RESISTANT COATING ON THE INSIDE

The Green Side of the Story

The L.L.B. required a custom-size, custom-printed box, and that was easy for us. Charlie was also adamant about using the greenest corrugated box available, and our Globe Guard® 100% recycled content corrugated box more than satisfied that requirement. For extra strength we designed an end load, full overlap end panel shipping box and helped him develop his artwork. We were pleased and proud when he decided to place our Globe Guard® logo next to his unique, striking Regulation Tactical logo.

Charlie went on to explain how our soldiers deployed overseas were “green” out of necessity, leaving no scrap of anything behind and reusing everything possible. They appreciated being able to reuse even a piece of corrugated board to write down coordinates, make notes or perhaps use it as impromptu stationary to send a quick note back home. He asked if it was possible to make the box out of “dry erase” material to make it easier for troops to use, wipe and reuse the corrugated surface.

The “erasable” request was a first, but we thought about the variety of standard coatings we were already using on the outside of boxes to resist moisture in an effort to extend their life cycle. We also considered the eco-friendly (recyclable and biodegradable) water-resistant coatings we add to the inside surface of products like our Globe Guard® cooler, so we provided Charlie with a coated sample to test and evaluate. He liked what we provided, and the inside coating became part of the spec for his boxes.

Those of us fortunate enough to be able to watch world conflict from the safety and comfort of our desk or favorite recliner can never sufficiently thank the men and women who willingly place themselves in harm’s way. We sincerely hope Charlie and his company, Regulation Tactical, succeed to make life a little easier and less painful for them. We at Salazar Packaging and Globe Guard® Products are just proud to be able to play a small, insignificant role in helping Charlie bring his valuable product to market.

Please contact Salazar Packaging if you have an unusual packaging application or need.

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Taking the Fear Out of Custom, Green Boxes

FOL BOX (LEFT) AND RSC BOX

Like most industries, the corrugated business loves acronyms, and these are two of the most common.

RSC Boxes

RSC stands for “regular slotted carton” and is the typical box construction that results in four flaps on the bottom box opening and four flaps at the top opening. On a rectangular box, the smaller side panel flaps are the minor flaps, and the larger, longer ones creating the box length are called the major panels. The key point distinguishing an RSC box is that the major panels meet in the middle where they are typically taped together using plastic or water-activated tape.

FOL boxes

This acronym stands for “Full Overlap,” which is what the flaps in this case do. In some cases, two panels are cut so they extend all the way to the opposite side, but in many cases all four panels are cut and designed to completely overlap. The photo above clearly shows the difference in the flap lengths on a similar size carton.

EXAMPLES OF TWO CUSTOM-PRINTED FOL BOXES

What’s the Difference?

The most obvious difference is that an FOL-style box essentially creates a double-, triple- or quadruple-wall box making it incredibly strong. The multiple, overlapping layers of corrugated prevent edge and corner damage, which is crucial, especially on a long box such as a 4”X4”X30” used to ship an item like an umbrella. A long box like that manufactured in an RSC-style can be quite vulnerable to crushing, making the FOL design the preferred, stronger structure.

Since the flaps are smaller/shorter on an RSC box, there is a slight cost advantage compared to the longer flaps on an FOL box. However, an FOL typically requires less tape to seal it. Oftentimes, a tape “tab” is all that is necessary to hold it closed. Also, short RSC flaps can sometimes be difficult and challenging to fold and secure because the short flaps want to spring back into an open position.

Does an FOL Box Require Special Tooling?

It depends on all three of the LXWXH dimensions, but in most cases the answer is no. The necessary longer/deeper slots can be made with standard tooling already available on most box-making equipment.

How Can Using More Corrugated Be Considered Sustainable Packaging?

I understand how to many a design that uses more square inches of corrugated might contradict green values or goals. However, that is not necessarily true if by using an FOL design you can:

1. reduce or minimize the board grade and “beef up” the box where you really need it.
2. avoid a costly, more wasteful corrugated design like a die-cut mailer.
3. minimize damage and the resulting replacement and reshipping.
4. eliminate interior or protective packaging that is often not very green at all, such as bubble wrap or peanuts.

As I have often said, there is no magic bullet or “one size fits all” solution. However, FOL designs are simply one more tool in the vast collection of resources we have available to help you solve your packaging problem with products that minimize your costs AND are also green.

Please contact Salazar Packaging if you have any questions or would like a no-cost, no-obligation review of your current or proposed package design.

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Ted and many of his staff are accomplished “barefoot” runners, and it was that passion for his sport that led him to create the premier huarache style sandal. I encourage every reader to visit the www.lunasandals.com web site and store to get a little flavor of this company, their people and the products they make.

A Great Brand in Need of Promotion

Anyone who has ever met me already knows I walk if necessary and run only when chased, and then only for very brief spurts. However, I do know a little bit about corrugated box design and the importance of branding, which is how we crossed paths with Luna Sandals.

The nice people at Luna wanted to create branded green packaging for shipping, and we suggested a die-cut mailer for strong construction and maximum billboard space for branding and printing purposes. We helped them through the process, making it as painless as possible. We:

1. helped them determine what style box was best for their application (in their case, a front-lock, die-cut mailer).
2. created a custom-size sample box to confirm it would fit their product style and sizes.
3. provided a template of the custom size they approved to assist them in the creation and placement of their artwork.
4. reviewed their artwork with them and made any last-minute suggested changes to be sure they were happy with the finished product.

A Perfect Application for Globe Guard® Brand Boxes

Globe Guard® die-cut mailer boxes are 100% recycled content and printed with vegetable-based inks. The quality and eco-friendliness of the packaging is consistent with our customers’ products, and Luna Sandals is a perfect example of our type of customer.

BTW, we liked the style and size of the Luna box so much that we decided to make it a stock (plain/unprinted) item. Check it out at our green packaging web store.

If you want to buy some really neat and unique footwear, please contact Luna Sandals. If you want packaging that does more than perform and actually communicates, contact Salazar Packaging for a no-cost, no-obligation review of your needs.

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NEW POLY MAILER AVAILABLE IN 8 STOCK SIZES

Whether you call them poly mailers, plastic envelopes or even courier mailers, plastic polyethylene-based mailer envelopes are very popular because they are inexpensive to buy and ship. They are, by far, the lightest mailer option available, which is increasingly important as mailing/shipping costs continue to climb. In addition, they are very secure, easy to use and moisture resistant.

We added this premium product line because there are applications that are best satisfied with a stronger, more attractive poly mailer, compared to our standard, recycled mailer product group. How do these mailers differ?

Recycled Poly Mailers                              Premium Poly Mailers

Grey outside/black inside                              White outside/silver inside

2.0 or 2.25 mils thick (varies by size)   2.5 or 2.75 mils thick (varies by size)

50 to 88% recycled content                             virgin LDPE resin

NEW PREMIUM (LEFT) AND RECYCLED POLY MAILERS

Features our Recycled and Premium Mailers Have in Common

Both are 100% recyclable as #4 plastic waste, and both are made for us by a leading American manufacturer, so you can count on consistent specs and quality. These standard and recycled mailers have also earned Globe Guard® review and approval based on almost 50 years of packaging industry experience and a lead position in packaging sustainability.

On Sale Plus Free Shipping!

We are truly excited about both poly mailer grades and are pleased to offer them through April 30, 2012, at a special introductory sale price. In addition, we will also ship either product anywhere in the continental USA for free. We are confident once you see the quality of our products that you will want to continue using them.

Please contact Salazar Packaging if you have any questions or would like to see samples of a particular size and grade.

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NEW 5-5-2 AND 12-5-2 DIE-CUT CORRUGATED MAILERS

Our two new sizes are ideal for shipping products in situations where a low profile or more attractive presentation type box is needed. These boxes are relatively inexpensive and require minimal void fill and tape to keep them closed and secure. Best of all, they are Globe Guard® die-cut mailers constructed of our strong, 32B-flute, 100% recycled content corrugated board.

New 13GGMT552 top tuck mailer

The inside dimensions are actually 5-13/16”X5-3/4”X1-15/16” high, and they come in convenient bundles of 50. Our flat-rate shipping program results in this product shipping anywhere in the continental USA for $5 per bundle.

This new size was requested by our subscription sample fulfillment, nutriceuticals, and jewelry customers who wanted something a little smaller than our very popular 7x7x2 tuck mailer. Void fill prices and shipping costs are rising, so using the smallest possible shipping box is important whether you are shipping a sample packet of organic honey or a handmade necklace.

New 13GGM1252 lock front mailer

The inside dimensions are 12-1/2”X5-1/2”X2-1/4”, and this mailer is also packed in bundles of 50 and ships for a very economical $10. On a longer mailer like this, we prefer lock front tabs for security and strength, making this an attractive, yet rugged, box. This new size was actually inspired by a new customer who sells and ships sandals but whose applications include a variety of long, low profile products.

CUSTOM PRINTING ON STOCK AND CUSTOM-SIZED MAILERS

Custom Printing and Branding

If you are a regular Globe Guard® customer, you know our stock mailers feature the Globe Guard® logo on the bottom panel to make sure your customers know you are using the greenest packaging possible. As always, all stock sizes, including these two new ones, are available custom-printed with your information for a surprisingly low additional cost. In most cases, a 1,000-box minimum applies for printing, and of course, a onetime print plate expense, but we will help you through the process and make it quick and painless.

May we add your size to stock?

Almost all of our box sizes began as specific customer requests, so if you have a particular size in mind and you don’t see it, please let us know. We are very likely to add it to our stock list if we are convinced other customers might also be able to use it.

As always, please contact Salazar Packaging with any questions about stock or custom size, plain or custom-printed mailers and RSC style shipping boxes.

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Our Poly Mailers Feature a Superior Adhesive Strip

A poly mailer is only as good as the adhesive that is used to seal it. Almost all mailers that are available on the internet or from catalog houses feature a “peel-and-seal” strip. Unfortunately, many of them offer a weak adhesive or one that is improperly applied. On many occasions, I have witnessed packers taping over the glue flap because they did not trust the adhesive strip.

Our mailers reduce packing time and expense because they feature the strongest available adhesive so your contents are sure to stay clean and secure during shipment without the need for additional taping.

3 OF 8 NEW SIZES OF GLOBE GUARD® POLY MAILERS

Our Poly Mailers Are Made in the USA

On the internet, you will find an assortment of similar products that are imported from overseas. Most offer minimal information, with even less guaranteed specs, because that provides the manufacturer maximum flexibility in how they are able to reduce their costs and ship them to the US. It also enables the importer to easily change vendors or even country of origin if they can get a better deal and lower cost from a different corner of the world. The bottom line is, you really don’t know what you are getting in terms of composition, recycled content, recyclability or even gauge.

Our mailers are made by a single domestic, highly regarded manufacturer. We do not casually jump from one source of supply to another, so we are able to clearly spell out our specs and deliver a consistent product to you. Our product descriptions include:

• Film composition and plastic recycling code
• Guaranteed film gauge (plus or minus industry standard 10%)
• American product dimensions and size code. For example, our 6” X 9” mailer is a US standard #0 mailer size.

Last, but not least, through the month of April, 2012, our poly mailers are going to ship for free, making them an even better deal.

Please contact Salazar Packaging if you have any questions or specific needs, such as custom sizes, custom printing or unique features like easy-open tear strips or even reusable (two-way) mailers.

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