Polyfoam - Products

Market: Manufacturing

Dual Solution – Dunnage & Shipping

Customer: Fraen

Fraen Corporation designed a stepper motor for Ford, but had not yet built the equipment to manufacture the motors – they were hoping to incorporate a dunnage tray into the manufacturing process, and then also use it for shipping the motors. With a robotically-loaded manufacturing system, the trays required extremely tight tolerances and consistency to accommodate the quarter-sized motor. The challenge was to find a tray that could meet the requirements of the manufacturing process, reduce labor, support and protect the delicate motors while providing a cost-effective shipping solution.

By designing an EPS foam tray, Polyfoam was able to find a solution that met both of Fraen’s needs. By engineering a tray that worked with the manufacturing equipment design, and had the tight tolerances necessary, the motors could be loaded automatically, which reduced the handling and labor of loading the motors. The trays were then placed directly into a box for shipment to the assembly facility which further saved handling and labor.