Tip of the Week - 08.12.09 - Cartons vs. Powerpacks
One of the biggest hidden costs in high quantity print projects are the costs associated with packing the final product into convenient sized cartons. There is labor and time involved in counting, packing, taping, and stacking boxes — not to mention the cost of the box itself. For example, one recent order for 15,000 catalogs resulted in over $2000 in cartoning charges. These charges are typically buried in the quote, or charged as an extra line item that — SURPRISE! — ends up coming to light when you get your final bill.
Since most high quantity projects end up being mass distributed — by mail, newspaper insertion, or pick-and-pack fulfillment — there isn't much of a need to have all of the pieces packaged in boxes. Instead, request bulk packing in Powerpacks (aka Gaylords) and your packaging costs will be reduced by 70-90%. Think of a Powerpack as a large box the size of a standard skid, about 3' tall. Items, like catalogs, are stacked inside of it loosely. When the Powerpack is full, a lid goes on top and gets secured onto a skid. The materials stay stacked up inside the Powerpack tightly instead of falling over. When the Powerpack gets to the mailhouse or fulfillment warehouse, they will remove the lid and simply take the product out of the Powerpack. This method is much easier than opening a bunch of boxes!
The only disadvantage of Powerpacks is the fact that they are nearly impossible to move without a forklift, and they can't be stored in a storage closet. This is inconsequential with most large projects simply because they get printed and mailed, or printed and shipped to a warehouse for storage. If you need a few boxes to keep on hand, simply request to have a small quantity packed in cartons.
So there you have it. Another "outside the box" (no pun intended) Tip of the Week designed to keep money in your pocket.