Load Securement Innovation for a Beverage Manufacturer
The Critical Role of Load Securement in Damage Prevention
Effective load containment is a fundamental requirement for damage-free shipping—especially in high-impact environments like rail transit. Without proper securement, even the most durable packaging can fail under stress, leading to costly damage, safety risks, and dissatisfied customers. This is especially true when transporting non-standard or uniquely shaped products that don’t conform to traditional palletized load patterns.
In these cases, understanding the interaction between product shape, load pattern, and containment method becomes critical. Unstable or top-heavy items—like tall bottles, oddly shaped containers, or mixed product loads—require innovative approaches to both packaging and palletization to prevent shifting, tipping, or collapse during transit. When shipments pass through high-impact scenarios such as hump yards or aggressive handling zones, the importance of tailored load securement strategies is magnified even further.
The following case study demonstrates how Group O partnered with a major beverage manufacturer to address recurring damage issues caused by railcar G-forces and unstable bottle design. Through a combination of custom load pattern engineering and advanced containment materials, Group O helped transform the manufacturer’s rail shipments into a safer, more cost-effective operation.
Situation
A leading beverage manufacturer was experiencing recurring product damage during railcar transit—particularly with a popular 46 oz bottle format. The tall, cylindrical shape of this bottle made it difficult to stabilize, especially when subjected to harsh rail conditions. Changes in rail routing meant shipments now passed through multiple hump yards, where they endured extreme G-forces—sometimes exceeding 8Gs—causing load shifts and frequent tipping.
To combat these issues, the manufacturer was using a costly and complex mix of materials: airbags, drop-down void fillers, corrugated shrouds, hexacomb panels, and a high-priced two-roll stretch film system. Yet, damage persisted, resulting in expensive cleanup, rejected shipments from major retailers, safety concerns, and mounting dissatisfaction across the supply chain.
Action
Group O introduced Shockgard, a high-performance load securement system designed for both railcars and containers. Working closely with the manufacturer’s logistics and warehouse teams, Group O designed a new load pattern and supported testing and implementation at two major production facilities.
The Shockgard solution replaced multiple packaging components—eliminating the need for shrouds, hexacomb, and backpacks — while also enabling a new, optimized load pattern that better stabilized the problematic bottle format.
In addition, the manufacturer removed outdated lumber rail systems and metal brackets inside their railcars, streamlining loading and improving safety for warehouse staff.
Results
Early trials show significant results, including:
Up to 98% reduction in product damage
Material cost savings by eliminating redundant or ineffective packaging components
Faster, safer loading processes
Lower cleanup labor costs
Improved retailer satisfaction and reduced shipment rejections
Potential to shift volume from LTL to rail, improving cost-efficiency
This strategic implementation of Shockgard has improved supply chain performance and paved the way for long-term logistics and packaging optimization. Contact Group O to optimize your packaging.
