Case study
Soudronic is a globally active, innovative industrial company and market leader in the manufacture of welding systems and production lines for metal packaging.
Soudronic customers benefit from fast spare parts supply around the clock and worldwide, which significantly minimizes downtimes. A large warehouse keeps over 40,000 original spare and wear parts ready for dispatch.
The product: DISCON roller heads
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The DISCON roller heads are the heart of the welding machines and a masterpiece of engineering.
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They were developed by Soudronic and are manufactured entirely in Bergdietikon.
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As wear parts, they have to be replaced regularly and are always available and ready for dispatch.
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Absolutely safe and environment-friendly packaging is essential for the valuable roller heads.
Until now, Soudronic has been using polystyrene packaging for shipping the roller heads. The accessories (syringe, rubber glove, sealing plugs, etc.) are also supplied in the compartments inside.
Our packaging goal:
Practical & environment-friendly
The development of two universal packaging solutions that efficiently accommodate all roller head variants with different dimensions and weights posed a particular challenge. These solutions had to be suiable for transporting a roller head, the central element of a welding machine, safely and upright in any size and weight class, from a minimum diameter of 36.5 mm and a weight of 300 g to a maximum diameter of 105 mm and a weight of 1.3 kg.
Our solutions:
The packaging solution from Prodinger Verpackung AG
Two different packaging formats have been developed for more than thirty roller head types with different dimensions and weights. In the new packaging, the roller heads are fixed and stabilized in a floating position in the center. This prevents damage to the transported goods if the box falls down.
Verification process
In several workshops, we adapted and further developed the packaging solutions in close collaboration with Soudronic and tailored them to the specific requirements. This iterative process ensured continuous optimization and perfection of our packaging.
The inlet of the packaging features an insert for stretching the film and a stabilization flap so that all axle heights of the roller heads can be properly packed. The height of the base has also been adjusted in various steps in order to achieve the "floating" position of the roller head.
To better secure the different axle diameters, a counter film is also stretched over the perforation at the bottom to hold the roller heads properly upright.
Various drop tests were carried out with both packaging formats to ensure that the valuable roller heads, which weigh up to 1.3 kg, survive a package drop undamaged.
To improve handling, we opted for a model with a quick-fold base for the outer packaging, specifically the Model Feco 0713 model.
Workplace and packaging process
In addition to the packaging process, a Soudronic apprentice has developed a "packaging device" as part of his final project. This device facilitates the packaging process efficiently by sucking in the film and fixing the outer packaging.
Base material: Inlet and outer packaging
Packing roller head workstation
Inserting the inlet to suck in the film
Roller head fixed with foil
Inlet with roller head
Filled and sealed outer packaging
The printing on the inlet and outer packaging complies with the latest packaging regulations.
Worldwide around the clock
This concept reflects the commitment of both companies to sustainability and environmental protection.
Safety
The valuable roller heads are absolutely safe and environment-friendly packed.
Sustainable and environment-friendly packaging
Reuse of packaging in case of returns.
Prodinger packaging -
Our responsibility
Our product range
Our range of films:
Our range of cardboard boxes:
Our range of adhesive tapes:
Our range of packaging papers:
Our range of cushioning material & load securing:
Our range of tools and machines:
Our range of office and shipping supplies:
from our extensive range.
