Challenges

Maintain structural integrity of the PDQ throughout a frozen, then thawed supply chain
Reduce set up time and complexity
Product weighs 32lbs.
Reduce or at least maintain total cost per product
Improve sustainability
Product cannot be weight bearing
Reinforce front lip to prevent tearing
Prevent sides and front supports from collapsing/imploding
Increase side to side compression strength
Eliminate layers

Solutions

Incorporate E-Z Set™ patented, PDQ structure with automatically set up reinforced stacking shoulders

Drastically reduced assembly time reducing the number of folds from 51 to 11
Reinforced stacking shoulders improved top to bottom compression. Safety factor above 7.
Corrugated board 40ECT B with a 33 medium and waterproof adhesive provided a sustainable, low-cost solution placing strength where it's needed, not wasted™
Superior front corner support increased stacking strength
Improved front rollover lip rigidity resists false scores, preventing imploding sides
Significant structural improvements enabled customer to increase product count 16%
Convenient side panel carry handles
Strong, double thickness stack tabs maintain PDQ's alignment, minimizing nest and eliminating the need for layer pads
Flute orientation coupled with other design features provide excellent side to side compression help prevent clamp damage
Reduced footprint of flat KDF blank improved sustainability, trailer efficiency, ease of handling plus more efficient use of storage and floor assembly areas

Added bonus:

To enhance the consumer experience, graphics were spruced up switching from one color print on flat mottled white paper to process direct print flexo
on high gloss semi paper

Crepes and Brioche 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 restacked on the CHEP pallet and stretch wrapped.
Other PDQ designs have trouble retaining structural integrity throughout a frozen, then thawed supply chain until the products are on display.
The alternative designs add setup time and complexity, and the products can only weigh 32lbs. E-Z Set™ PDQ aims to reduce or maintain total cost of product, with better stability, and simpler assembly.

Challenges

Solutions

E-Z Set™ patented PDQ solutions:

Designed two EB double wall one piece E-Z Set™ PDQ's
Stacking shoulders, front corner columns and reinforced front lip, easily handled up to 80lbs. per PDQ
E-Z Set™ mechanism also provide a strong and secure hand hold to safely stack trays when building the pallet

Strength where it's needed, not wasted™

Challenges

Solutions

Incorporating E-Z Set's™ patented glued, auto set up shoulder mechanism makes assembly quick, easy and intuitive requiring minimal training
Typical set up time <10 seconds. Sets up lie regular shipping RSC boxes.
E-Z Set™ Stacking shoulders provide excellent top to bottom compression strength easily supporting 24lbs. per PDQ with a safety factor above 5.
E-Z Set™ Stacking shoulders reduce PDQ's from nesting
Reinforced double thickness front access panel resists false scores/deflection
Integral glued in divider provides additional stacking strength, minimizes product shift and resists PDQ's nesting when stacked on top of each other
Corrugated board 32ECT B with a 33 medium and waterproof adhesive provided a sustainable, low-cost solution placing strength where it's needed, not wasted