COST EFFECTIVE

Strength where it's needed not wasted™

A dollars and cents tangible measurement of material cost reductions resulting from superior strength inherent in all E-Z Set™ PDQ designs.

It's simply math!

Using 52# Kraft liner as a benchmark, based on a published cost per ton, the material cost savings as a percentage, to a lower basis weight would be

52# - 42# - 19%

42# - 35# - 15%

35# - 30HP# - 15%

Using 56# MW liner aas a benchmark, based on a published cost per ton, the material cost savings as a percentage, to a lower basis weight would be

56 MW# - 42MW# - 25%

42 MW - 35MW - 13%

Using 40# medium as a benchmark, based on a published cost per ton, the material cost savings as a percentage, to a lower basis weight would be

40# medium - 33# medium - 8%

33# medium - 23# medium - 30%

Throughout this website are examples of proven E-Z Set™ PDQ’s substantiating this claim.

Below are a few examples

Lower basis weight liners and mediums lowering total cost
Less board
Our patented glued stacking shoulders providing stronger stacking strength while reducing corrugated material
Top to bottom and side to side compression strength reducing sidewall and front lip failures that many existing PDQ’s ineffectively address adding heavier weight corrugated and additional board.
Cross corrugated double, triple ply reinforcement
Reducing unnecessary full depth backwalls. While some may not like the partial back, the only time it is visible in use is when virtually all the product is sold. It’s not how the PDQ looks empty in an office environment but after surviving the rigors of the supply chain.

Lowering total cost while improving structure integrity

Challenges

Survive the rigors of a very challenging frozen and thawed at store level supply chain

Lower material and assembly cost

The rolls are frozen then packed in a PDQ. The product can be stored up to a year. Since the product has a limited shelf life once thawed, the pouches of rolls need to be date coded before shipping to the club store. It is not feasible to do this as part of the internal production process.

To maintain freshness, as orders are released to the club store, their 3PL warehouses unwrap each skid, remove each PDQ, remove the product pouch to be date coded, repacked and restocked on the CHEP pallet and stretch wrapped.

Reduce product damage/returns due to PDQ's nesting inside the PDQ below squishing the rolls

Existing design failed due to tearing on front lip and imploding side panels

Extremely cumbersome to assemble

Facilitates easier set up of the stacking shoulders and entire PDQ

Superior front corner support for improved top to bottom compression

Preferred embodiments significantly improve side to side compression

Before

Total costs including assembly, better pallet, warehouse and truck utilization were similar but with the E-Z Set™ design the customer got significantly more bang for their buck.

Refrigerated PDQ's often are moved around with clamp trucks sending layers to smaller club stores. The flute orientation and other patent preferred embodiments withstand the stress when clamp trucks are used due to excellent side to side compression on the front of the box.

Special patented E-Z Set™* design embodiments improve front panel rigidity,

resisting false scores and tears which caused the existing design to implode.

Working in combination with the E-Z Set™ stacking shoulders provided an

effective solution minimizing nesting inside the PDQ below and prevented

squishing the rolls.

PDQ's that don't requirement in-store maintenance are diffidently important. PDQ's

that require things such as taping torn front lips or imploding sidewalls could result in

reports to the club store manager who in turn informs the buyer, typically with pictures.

This obviously is not a good thing and could jeopardize future orders. In other cases,

such as this, when a PDQ fails, the solution is to over engineer the structure and beef up

the paper weights. Frequently the designs still miss the boat as they focus more on the

stacking strength. All they do is add material and assembly cost.

On a similar E-Z Set™ PDQ, the product weight was increased to 32 lbs. and enabled the

club store vendor to add 3 more pouches prorating the costs of the display and freight

over 14% more product.

This helped offset some of the costs of the upgraded graphics thus enhancing the

consumer experience.

After

Our successful solution

How would your PDQ design "stack up"?

“When is saving money, not truly saving money?”

Dog Treats Cost Reduction Case Study Goals and Solutions

Reduce material cost by eliminating packaging components, total square footage of corrugated and basis weights
Reduce labor cost and time to market
Improve structural integrity, product access and visibility
Increase # of sell units per pallet
More sustainable, decreasing carbon footprint

Utilizing our patented design elements, incorporated into our E-Z Set™ sample, we achieved :

One common size PDQ 23 x 15 footprint 5 down, 25 PDQ’s per pallet, 39 3⁄4 x 47 3⁄4
One piece PDQ construction with integral divider. No partitions needed!
PDQ 44 15/16 x 69.9 21.9 square feet, reduced sq. ft. vs current 20 x 20 PDQ by 14%
recommended 10 pt-33-42 B board combination reduced basis weights by 35%.
Changing from C flute to B improved truck & warehouse by 33%
11 pouch product orientation yields 275 Pouches per pallet
Significantly more product per pallet, more revenue$/sales floor square footage
Reduced footprint and number of corrugated SKU’s reduces assembly line floor space.
Decrease carbon footprint by reducing the number of SKU’s and manufacturing operations
Folded and glued blank reduces floor space from 3 pallets per PDQ to one pallet with 250 PDQ’s

Putting “Strength where it’s needed, not wasted” resulted in eliminating 44 total pieces of corrugated

3-layer pads
A bottom tray
20 two-piece sets of partitions

Drastically quicker and easier to set up due to patented design features (See Video)

intuitive assembly process
easier to train set up a typically transient assembly workforce
Less number of “touches
easier to manage smaller PDQ footprint
Less corrugated SKU’s
Less floor space

Reduce material cost by eliminating packaging components, total square footage of corrugated and basis weights
Reduce labor cost and time to market
Improve structural integrity, product access and visibility
Increase # of sell units per pallet
More sustainable, decreasing carbon footprint

Utilizing our patented design elements, incorporated into our E-Z Set™ sample, we achieved :

One common size PDQ 23 x 15 footprint 5 down, 25 PDQ’s per pallet, 39 3⁄4 x 47 3⁄4
One piece PDQ construction with integral divider. No partitions needed!
PDQ 44 15/16 x 69.9 21.9 square feet, reduced sq. ft. vs current 20 x 20 PDQ by 14%
recommended 10 pt-33-42 B board combination reduced basis weights by 35%.
Changing from C flute to B improved truck & warehouse by 33%
11 pouch product orientation yields 275 Pouches per pallet
Significantly more product per pallet, more revenue$/sales floor square footage
Reduced footprint and number of corrugated SKU’s reduces assembly line floor space.
Decrease carbon footprint by reducing the number of SKU’s and manufacturing operations
Folded and glued blank reduces floor space from 3 pallets per PDQ to one pallet with 250 PDQ’s

Putting “Strength where it’s needed, not wasted” resulted in eliminating 44 total pieces of corrugated

3-layer pads
A bottom tray
20 two-piece sets of partitions

Drastically quicker and easier to set up due to patented design features (See Video)

intuitive assembly process
easier to train set up a typically transient assembly workforce
Less number of “touches
easier to manage smaller PDQ footprint
Less corrugated SKU’s
Less floor space

Does a unglued diet cut PDQ save money?

The design below saves a total of:

33% board reduced 19% outer liner cost

15% inner liner cost

Due to refrigerated supply chain, we added WPA increasing board cost 1.5% but Strength where it’s needed, not wasted” justify the nominal extra cost

Total PDQ and separate divider board usage:

14.1 SQ. FT.

This E-Z Set™ design average set up time less than 20 seconds. This is 3 times faster than the above two piece construction

9.39 SQ FT

Folded size 24 ½ x 40

2 on footprint 49 x 40

Minimal overhang.

Fits in storage racks.

42 MW-33-35 B with WPA