How Packaging Automation Reduced Damage and Cut Packaging Time by Over 50%

Customer Perspective

"As a packaging distributor, it's all about solving problems, including problems a client may not even realize they have."

Neal Magaziner
General Manager, Imperial Brady

When a major U.S. automotive manufacturer experienced challenges packaging vehicle headlamps, Imperial Brady identified an opportunity to improve both packaging speed and product protection with an innovative air cushioning solution.

The Challenge

During a facility assessment, Imperial Brady evaluated the customer's existing suspension packaging used to protect automotive headlamps during shipment.

The assessment uncovered several operational challenges.

The packaging process was labor-intensive and time-consuming, requiring associates to carefully position each headlamp within the suspension pack. Even with careful handling, improperly positioned products were susceptible to damage during transit, increasing replacement costs and slowing production.

The manufacturer needed a solution that could improve throughput while providing better protection for one of its most fragile vehicle components.

The Solution

Working alongside Pregis, Imperial Brady introduced ChamberPak, an advanced inflatable protective packaging system designed to simplify the packaging process while improving product protection.

Unlike the previous suspension packaging, ChamberPak created a protective air chamber around each headlamp, making packaging faster, more consistent, and easier for associates to perform.

The solution also optimized packaging space without compromising product protection, allowing the manufacturer to improve operational efficiency while reducing transportation damage.

Most importantly, the improved process required fewer associates to complete the same packaging workload, helping free labor for higher-value production activities.

Delivering Measurable Results

The new packaging solution produced immediate improvements throughout the operation.

Packaging time dropped from 1 minute and 4 seconds to just 29 seconds per headlamp, reducing packaging time by more than 50%.

Transit damage rates also improved dramatically, falling from more than 5% to less than 1%, significantly reducing replacement costs while improving customer satisfaction.

By combining faster packaging with superior protection, the manufacturer was able to increase productivity without sacrificing product quality.

A Better Way to Protect Automotive Components

Protective packaging should do more than prevent damage—it should improve efficiency throughout the supply chain.

By evaluating existing processes and introducing innovative packaging technologies, Imperial Brady helps manufacturers reduce labor requirements, improve packaging consistency, and protect high-value products during shipment.

Whether shipping automotive components, industrial equipment, or fragile manufactured goods, the right packaging solution can create measurable operational improvements across every stage of production.

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