Proper and suitable packaging is an indispensable part of the logistics and transportation process, especially when it comes to machinery. The safety and integrity of equipment and components during transportation must be ensured to avoid costly damage. In this article, we will take a closer look at the necessary measures for packaging machines safely for transportation.
GENERAL INFORMATION AND REASONS FOR THE NECESSITY OF TRANSPORT PACKAGING FOR MACHINES
The reasons for appropriate transport packaging of machines are obvious:
- High-quality packaging protects the machines from damage such as knocks, drops or vibrations during transportation. Suitable packaging reduces the risk of damage caused by external influences such as moisture, temperature fluctuations or dust.
- In addition, correct packaging facilitates efficient transportation and handling of the machines, resulting in time and cost savings.
- The transport packaging also serves as an information medium, for example as a carrier of necessary details (freight numbers, information on the center of gravity, warnings, etc.).
To determine the necessary packaging measures , the following properties of the transported goods must be inspected and recorded:
- the technical capabilities of the machine
- the dimensions
- the weight
- the position of the load’s center of gravity
- Particularly sensitive parts
The preliminary inspection also serves to determine which tools and packaging materials need to be used. Finally, a decision is made as to which lifting tools (cranes, crane trucks or forklift trucks, etc.) are required and which means of transportation is suitable for the packaged machine.
Consideration of weather conditions
The climatic conditions during transportation are also an important factor that must be considered. Depending on the type of machine, sub-zero temperatures or excessive heat, rain, snow, ice and strong winds can occur and the packaging must be adapted accordingly.
In the case of sea transport, particular attention must be paid to salt water, which can also have an effect via the humidity and makes special protective measures necessary.
Type of transportation
Whether a machine is transported by truck, rail, air freight or ship is also decisive. The different means of transportation mean different requirements in terms of fastening options, handling, dimensions or even regulations:
These not only guarantee that assembly processes are completed quickly. They also help to prevent damage during the work. The range of special tools and solutions for machine assembly is very extensive. Below we provide a brief overview, which cannot claim to be exhaustive – because the selection for the various areas of application is too large for that.
- Transportation by road: ADR (Agreement concerning the International Carriage of Dangerous Goods by Road)
- Transportation by sea: IMDG (International Maritime Dangerous Goods Code)
- Transportation by air: IATA (recommendations and guidelines of the International Air Transport Association)
- Transport by rail: RID (Regulations concerning the International Carriage of Dangerous Goods by Rail)
Transportation of hazardous goods
When transporting machines or associated parts, hazardous substances may be integrated, for which there are special requirements. Dangerous goods include, for example, operating materials such as hydraulic oils, lubricants, air conditioning gases in cooling units or lithium batteries.
Before transportation, it must therefore be clarified whether the machine contains such substances. Information on this can be found in the safety data sheets for the respective substances, where any dangerous goods classification is declared. If this is the case, the next step is to determine which packaging and hazardous goods labeling are required for transport.
PACKAGING MATERIALS AND PACKAGING SOLUTIONS FOR MACHINERY TRANSPORTATION
There are a variety of packaging materials and packaging solutions that can be used for the safe transportation of machinery. It is important to choose the right material and the right solution according to the type of machine, its size, its weight and the type of transportation route.
Wooden crates
They are one of the most common packaging options for transporting machinery. They offer good stability and protection against external influences. However, when using wooden crates, the regulations for handling wood in accordance with the international ISPM 15 standards must be observed, especially for imports and exports. They must be of the correct size and strength to safely accommodate the machine.
Customized packaging boxes
Depending on the dimensions of the machine to be transported, the packaging crates are often made to measure. Several important points can be taken into account here:
- Best possible protection of the transported goods
- Optimum utilization of storage space
- Optimum handling (can be driven under by forklift truck, marking of heavy and/or lashing points on the crate, etc.)
For smaller machines, a combination of wooden crate and cardboard packaging can also be used to save costs. For heavier machines, it is advisable to use special transport containers such as steel frames or containers.
Approved crates
So-called approved crates – usually made of plywood with reinforced edges – are explicitly intended for the transportation of hazardous goods. The 4D and 4DV crates are available in various defined dimensions. The parts transported in them must also be provided with the necessary inner packaging. This can be special canisters, additional film packaging for machine parts or agents for moisture control.
The dangerous goods contained in the crate must be marked in accordance with international regulations (4D code with UN symbol, country code, proof of approval, etc.).
Pallets for machine transportation
Transporting a machine on a pallet makes handling easier. The freight can then be moved with the help of forklifts, for example. However, the usual standard pallets quickly reach their capacity limits. On the one hand due to the dimensions, on the other hand due to the maximum possible load.
Suppliers of customized packaging solutions (both pallets and crates) can use special software to plan the packaging elements individually and thus guarantee and verify sufficient statics and stability. IPPC labeling for pest-free wood (in accordance with national plant protection regulations – International Plant Protection Convention) is also standard here.
OVERVIEW PALLET DIMENSIONS
| Pallet type | Dimensions (L x W x H) | possible load * |
| Euro pallet (according to EN 13698-1) |
100 x 80 x 14.4 cm | Point load: 1,000 kg Max. load capacity: 1,500 kg with even distribution |
| Industrial pallet (according to DIN 15146) |
120 x 100 x 14.4 cm (3 runners) 120 x 100 x 16.2 cm (base frame) |
1,250 – 1,500 kg 1,250 – 1,500 kg Individual solutions offer a higher load capacity |
| Large pallet | No standardized dimensions, common sizes: 200 x 120 x 14.4 cm 200 x 125 x 14.4 cm |
individual, depending on design |
| Container pallets (made of pressed wood) |
Type F 10 / EPAL CP1 format: 100 x 120 x 13.8 cm Type F 11 / EPAL CP3 format: 114 x 114 x 13.8 cm |
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– – |
| Air freight pallets (made of aluminum)** |
LD7 pallet (code: PAG, PAJ, P1P): 318 x 224 cm LD7 pallet (code: PMC, PQP): 318 x 244 cm |
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* The specifications here refer to the dynamic load capacity of the pallets. This is the maximum load capacity when the pallet is moved together with the load using a forklift or pallet truck. The static load capacity is usually higher. This value refers to the maximum load capacity if the pallet is not moved – for example, if it is only used in a warehouse.
** Sustainable cardboard pallets are now also available for air freight. However, these are generally not suitable for the heavy weights involved in transporting machinery.
MOISTURE PROTECTION FOR MACHINE TRANSPORTS
Certain machines must also be protected against the effects of moisture. A good basis is the use of corrosion protection oils or special VCI fluids (Volatile Corrosion Inhibitor). These can be used to treat the machines or components and spare parts directly.
Another possible measure is the use of desiccants, which are added directly to the packaging box. The bags contain bentonite, for example, which can remove moisture from the environment. It is important to provide the right amount of desiccant for the goods being transported.
Film bags are used for more compact pieces. For larger elements, there are special shrink films that enclose the components compactly. Alternatively, the machines can be protected with wrapping film.
The safety measures are rounded off with VCI films or papers. The packaging materials are treated with corrosion-preventing substances and can evaporate these again. This provides the necessary protective layer for the packaged goods.
It is important that the packaged parts are clean and dry beforehand. While VCI-treated packaging does not have to be airtight, this is absolutely necessary when using desiccants to prevent further moisture from penetrating during transportation.
The special case of sea freight
If machines, machine parts or entire production plants are to be exported to countries on other continents such as Africa, America, Asia or Australia, this is usually done by sea. The crossing can take a very long time in some circumstances, especially if intermediate storage or transshipment in another port is required.
Accordingly, the cargo must be packed seaworthy before it is loaded onto a ship in its home port. Salt water and salty air can cause major damage to high-tech machinery if it is not adequately protected from the weather conditions on the oceans.
All components of the machine to be transported must be completely dry before packing. Modern drying and blowing technology can be used to effectively help with this in conjunction with pre-cleaning. The above-mentioned measures are used to regulate humidity.
The packaging should be particularly robust and stable for sea transportation so that it is not damaged by the strong movements of the ship in heavy seas or storms. Appropriate securing against shifting should also be included in the planning.
Special case air freight
Weight plays a special role in this mode of transportation. This is why lightweight yet stable and highly resilient aluminium pallets are used here, which are also optimized for the dimensions of certain aircraft.
There are also other standardized air freight containers (ULD – Unit Load Devices). They are classified according to their dimensions and other details with a code and can therefore be selected for the appropriate aircraft types.
The relevant import and export regulations must also be observed for this transport route.
Special case of transport by rail
As a provider, DB Cargo has its own requirements that must be met when transporting machinery by rail. The general terms and conditions of service state the following on this subject:
“The consignor must pack the goods, insofar as their nature requires packaging, in such a way that they are protected against total or partial loss and against damage during transportation and cannot injure persons or damage equipment or other goods. In addition, the packaging must comply with any special packaging provisions of the carrier.”
The special packaging provisions may include additional regulations – also depending on whether the machine is being transported domestically or abroad. If necessary, additional measures for compliance with customs regulations must then be taken into account.
Overall, of course, the dimensions of the loading units, i.e. the respective wagons, must be adhered to. These can vary depending on whether open trailers or closed wagons are used.
SOLUTIONS FOR LOAD SECURING
In addition to choosing the right packaging material, the appropriate fastening elements must also be selected – suitable for the respective means of transportation. Straps, padding and foam inserts should be used to secure the load. These elements not only protect the machine from damage during transportation, but also prevent it from slipping inside the packaging.
Image 1: Adobe Stock © Mixage
Image 2: Adobe Stock © industrieblick
Image 3: Adobe Stock © Oli_ok
Image 4: Adobe Stock © Chalabala
