UPAC, a leading food bagging solutions provider, partnered with CUBEB, a prominent party ice manufacturer, to supply 5 kg plastic bags for their product packaging. Recognising the challenges in pallet stability during palletisation and transportation, UPAC implemented innovative design and material improvements to enhance load security, reduce product damage, and optimise logistics efficiency.

Challenges

• Unstable Pallets: Poor stacking strength caused toppling during palletisation and transit

• Product Damage: Thin bags led to tears and bursts

• Inefficient Handling: Unstable loads slowed operations and raised labour costs
• Sustainability Goals: Need to reduce plastic without compromising durability

UPAC’s Solutions

1. Anti-Slip Bag Exterior

• Problem: High slip surfaces caused slippage and load shift
• Solution: Micro-embossed textures for better friction
• Impact: 40% reduction in load shifts
  
  

2. Material Optimisation

• Problem: Original 50-micron bags are prone to damage and splitting
• Solution: Advanced LDPE formulation at 45 microns
• Impact: 10% plastic reduction with durability
  
  

3. Pallet-Optimised Dimensions

• Problem: Mismatched sizing caused uneven stacks
• Solution: Custom-fit bags for standard pallets 
• Impact: 15% increased load capacity

Results

UPAC’s redesign enhanced performance (pallet stability, durability) and sustainability (10% plastic reduction). By optimising materials and dimensions, we helped CUBEB reduce costs, minimise waste, and improve supply chain efficiency while meeting environmental goals.

Disclaimer:
“CUBED” represents a confidential UPAC client. All data and results are factual but anonymised to protect proprietary information.