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Pallets are an integral part of the product transportation-that much will never change. However, a new pallet handling system has been designed by Charles Kiolbasa, chairman and founder of Layer Saver, Hinsdale, IL.
Layer Saver is a collapsible, reusable, two-layered pallet shipping vessel made from plastic. The unit consists of a base and a supporting frame that is composed of plastic and steel bars. Within this, it can hold a standard plastic pallet with several rows of corrugated cartons on it, or just hand-stacked items. It also provides a sturdy base that another pallet of goods can sit on top of-allowing 25 to 50 percent more product within the same footprint.
"It's a flexible design that lends itself to every aspect of shipping products from the DC to the store," says Kiolbasa. Shippers can store fragile or irregularly-shaped items, or odd-sized loads in the first level-say a few cases of linguini, or bags of charcoal briquettes-items that might be damaged or crush other items if haphazardly packed into a truck. "You can stack a case of toilet paper on the next level."
One of Layer Savers' clients, by combining pallets and hand stacked items in the units, has lowered the trucks leaving its DC from 40 to 25. "An astronomical savings," says Kiolbasa.
A typical truckload would see 10 to 12 of the 40-inch x 48-inch Layer Saver units, mixed in with standard pallets, he adds.
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