The client engaged with us to develop a tailored AIR|SHIELD™ inflatable protective system, creating an on-demand inflatable barrier around each windscreen.
The Challenge
The client supplies windscreens and panoramic glass to multiple aftermarket retailers and Car Dealers across the Globe. Their existing packaging system involved corrugated cartons with foam buffers and corner guards, which led to:
- High breakage rates during transit due to insufficient cushioning
- Bulky packaging and high transport costs
- Manual handling challenges and inconsistent pack performance
- Difficulty scaling for different glass sizes and curvatures
Our Solution
The client engaged with us to develop a tailored AIR|SHIELD™ inflatable protective system, creating an on-demand inflatable barrier around each windscreen.
AIR|SHIELD™ Key Features for Windscreens:
- Custom-fit inflatable wraps and edge buffers for varied windscreen sizes
- On-demand inflation at packing stations to reduce storage and waste
- Designed to form a rigid air-cushioned shell, absorbing shock and vibration
- Flexible enough to accommodate both flat and curved glass
- Integration with standard outer cartons or custom crates
| KPI | Pre-AIR|SHIELD | Post-AIR|SHIELD |
| Transit Breakage Rate | 4.10% | 0.40% |
| Avg. Packaging Time (per unit) | 6 mins | 3.5 mins |
| Storage Footprint (protective packs) | 10 Pallets | 2 Pallets |
| Pack Material Weight per unit | 2.8kg | 0.9kg |
| Recyclability of Materials | 55% | 70% |
“This has been a transformative shift for us. We’ve reduced glass damage dramatically while freeing up space and reducing packaging waste. Our warehouse team love the simplicity, and AIR|SHIELD™ gave us a flexible packaging model for our growing product range.”
Logistics Manager
EU Automotive Aftersales Division
