Traditionally, wooden drums are used
to transport power conductors &
cables in India. T o pack 1.1 MT of
conductors pa (Indian market size),
about 0.6 million trees are cut. T o
address this, Sterlite T echnologies
used returnable steel drums for
packaging & transportation of its
power products.The innovation has
saved 32,000 trees in a year and
slashed packaging cost by a whopping
60 per cent!
Sterlite Technologies (STL), an end-toend power and telecom solutions
provider, is the 7th largest
manufacturer of Telecom and Power
products & services globally . The
company was facing transportation
challenges for its power conductors
and cables products due to wooden
drums which are used for packaging.
These products are sensitive to
damage during handling, storage and
installation. Any damage degrades
product performance to the extent
that replacement becomes necessary.
Increasing product lines, recurring cost
of drums, and increased packaging
weight had generated the need to
address the issue immediately.
The packaging innovation
T o solve this, Sterlite came up with
the innovation of shifting packaging
material from wood to steel with
returnable model.Sterlite introduced
a new approach to storage/shipments
of power transmission conductors,
combining packaging improvements as well as switching from wooden
drums, to steel drums.Since its
inception, this initiativ e has helped
the company reduce wood
consumption, eliminate quality
complaints due to fungus and nail
damages to the product, and gain
substantial savings on recurring cost
of drums.
Sterlite also proposed its customers
to shift packaging material from
wood to steel with returnable model
wherein, detailed study, analysis, and
trials were conducted in the presence
of the customers.After necessary
trials and inspection, the company's
major customer, PGCIL , approved
usage of steel drum on returnable
basis followed by private companies
like Adani & Essar. Thus, all the
shipments were moved to steel drum
returnable model.
Size optimisation for logistics efficiency
In view of the sturdiness of the steel
drum, it is possible to select and
standardise one drum size which is
suitable for a range of loads and
conductor lengths.Sterlite
maximised the conductor/cable
weight per drum and accordingly,
worked towards increasing the
standard length of conductor per
drum.
The key factors such as conductor
manufacturing machine capacity,
load carrying capacity of the drum,
transport efficiency optimisation for
outbound drums by making the
dimensions compatible with
common truck and trailer sizes,
handling capability of gross weight at
site for unloading & stringing,
availability of raw material like steel & HDPE sheets, were critically evaluated
before finalisation of drum
dimensions and conductors with
standard lengths & loads.
Additionally , Sterlite approached their
customers to move from wooden
battens to PP Sheet for outer covering
of conductors.PP sheet is a new
option for the replacement of wooden
lagging.Extensive testing was done by
Sterlite and the returnable steel drum
came out as a usable packaging
solution for safe delivery of Sterlite's
products to the customers.
Key benefits
Some of the major benefits include
good impact and puncture resistance
in case of mechanical collision,
mechanical shock absorption without
transfer to conductor, good ESCR Long lifetime, impervious to climatic
change or UV exposure, zero risk of
deterioration and fungus formation,
eco-friendly and recyclable upto 4
times, no risk of nail damage to
conductors, fast unpacking at
installation site, and easy refitting
after part drum installation.
If this solution is replicated in the
Indian power conductors' business,
whose size is 1.15 MTP A, close to 6
lakh trees would be saved annually .
Since implementation of sustainable
packaging, Sterlite has saved nearly
32,000 trees a year. Also, due to size
optimisation of all-steel drums, it is
possible to select one drum size
suitable for a range of loads and
conductor lengths.This has resulted
in minimal stocking of inventory as
well. The company has won the
Manufacturing Supply Chain A wards
2016 for the implementation of this
innovation.
Future prospects
With the successful implementation
and positive response from Sterlite's
customers, the company is aiming at
100% adoption of sustainable
packaging across Sterlite's Optical
Fibre Cable & Power Units further
extending the ecological benefits of
the innovation.
Caption: Sterlite's returnable steel
drums are weather resistant, free
from transit damage, and easily
transportable at site as compared to
wooden drums.Being recyclable,
they have a scrap value as well.
, an end-to-end power and telecom solutions provider, is the 7th largest manufacturer of Telecom and Power products & services globally. The company was facing transportation challenges for its power conductors and cables products due to wooden drums which are used for packaging. These products are sensitive to damage during handling, storage and installation. Any damage degrades product performance to the extent that replacement becomes necessary. Increasing product lines, recurring cost of drums, and increased packaging weight had generated the need to address the issue immediately. To solve this, Sterlite came up with the innovation of shifting packaging material from wood to steel with returnable model. Sterlite introduced a new approach to storage/shipments of power transmission conductors, combining packaging improvements as well as switching from wooden drums, to steel drums. Since its inception, this initiative has helped the company reduce wood consumption, eliminate quality complaints due to fungus and nail damages to the product, and gain substantial savings on recurring cost of drums.', '../https://www.stl.tech/sterlite-live/blog_banners/36/medium/steel-drum36f5.jpg?1459945674', 'sterlite-technologies-saves-60-packaging-cost-through-returnable-steel-drums.html')){kind=link}
, an end-to-end powe...', '../https://www.stl.tech/sterlite-live/blog_banners/36/medium/steel-drum36f5.jpg?1459945674', 'sterlite-technologies-saves-60-packaging-cost-through-returnable-steel-drums.html')){kind=link}