Case Study: Custom Foldable Plywood Boxes for Long Industrial Components

Background: A family-owned manufacturer of mobile lifting equipment based in Germany

Background: A family-owned manufacturer of mobile lifting equipment based in Germany
A family-owned manufacturer of mobile lifting equipment based in Germany required a reliable packaging solution for transporting long, high-value crane components across Europe. While their products were engineered with extreme precision, their logistics team identified packaging as a critical risk factor for damage, handling inefficiency, and transport costs.
The company contacted ZAMKO with a specific request: foldable wooden boxes in non-standard lengths for one-way shipments.
Initial Requirements
• Foldable plywood boxes
• Lengths: 2400 mm, 3200 mm, 4200 mm
• One-way transport to end customers
• High load stability and protection
• Cost-efficient packaging without return logistics
A first order of 150 foldable plywood boxes was delivered according to these specifications.
On-Site Analysis and Technical Partnership
Following the first delivery, the customer requested a modification to the pallet base. Instead of implementing isolated changes, ZAMKO proposed an on-site visit to review the full packing, handling, and loading process.
During the factory walkthrough, several hidden inefficiencies and handling risks were identified-particularly during forklift operations and load securing. These insights formed the basis for a comprehensive redesign, which was immediately implemented in the second production run.
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Identified Challenges and Implemented Solutions
1. Pallet Bending During Forklift Center Pick-Up
Challenge:
Due to space constraints, forklifts lifted long crates from the center. This caused pallet deflection, leading to pressure points and potential damage to crane components.
Solution:
• Side opening in the pallet structure allowing safe center pick-up
• Custom internal wooden supports aligned with forklift load points to distribute weight evenly
Result:
• No pallet bending during lifting
• Improved load stability
• Reduced risk of internal product damage
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2. Flexible Strapping for Variable Product Geometries
Challenge:
Crane components varied in width, shape, and strapping requirements. Fixed tie-down points slowed packing and increased handling effort.
Solution:
• Complete redesign of the upper deck
• Plank spacing of approx. 50 mm, creating continuous strapping options across the entire surface
Result:
• Faster and safer strapping
• Reduced packing time per crate
• Greater flexibility for different product variants
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3. Optimised Wall Heights for Transport Efficiency
Challenge:
Not all shipments required full wall height, resulting in unnecessary volume usage and higher transport costs.
Solution:
• Two compatible wall-height options:
o Standard height for large and complex cranes
o Reduced height for compact components
Result:
• Improved truck loading efficiency
• Lower transport volume and cost per shipment
• Packaging tailored to specific product groups
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Project Results at a Glance
The customer achieved measurable improvements across their logistics process:
• Safer handling of long, heavy components
• Reduced risk of transport damage
• Shorter packing times
• Improved truck utilisation
• Modular packaging adapted to different crane types
• A long-term packaging partner with logistics expertise
As one of the customer’s engineers summarised:
“We were looking for boxes. What we received was a complete packaging solution that changed how we ship our products.”
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Conclusion
This project demonstrates that industrial packaging is a critical part of the logistics chain, not just a container. By combining on-site analysis, technical engineering, and customised design, ZAMKO delivered a solution that continues to generate value with every shipment.

Read more HERE:
https://zamko.eu/how-a-family-manufacturer-transformed-long-goods-packaging-with-tailor-made-foldable-plywood-boxes/
Or see the video CASE STUDY here:
https://www.youtube.com/watch?v=Nyo7MpQnwTs
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