Panel participants from left to right: Paul Kamholz, VP of Sales at Cabka (moderator), Axel Breitkreuz, VP of Sales at ID Plastics, Matt Shuert, President of Shuert Technologies, Jorge Precadio Carpio, CEO of Hiperpack, and Dan Delorey, Reusable Packaging Specialist at Technology Container Corporation.

As the conversation around bulk packaging evolves, sleeve packs have become central to the discussion. These reusable bulk shipping units, consisting of a pallet base, a foldable plastic or corrugated sleeve, and a top lid, have gained significant traction due to their lightweight yet durable design, efficient shipping density, and ability to be tailored to specific supply chain needs. From auto parts to preforms to textiles, the range of use cases continues to expand. Sleeve packs are also known as sleeve box and pallet pack.

At PACK EXPO International 2024 in Chicago, sleeve pack thought leaders convened to discuss the history, benefits, and challenges of this versatile product, particularly regarding customization, sustainability, and standardization. The panel featured Paul Kamholz, VP of Sales at Cabka (moderator), Matt Shuert, President of Shuert Technologies, Axel Breitkreuz, VP of Sales at ID Plastics, Jorge Precadio Carpio, CEO of Hiperpack, and Dan Delorey, Reusable Packaging Specialist at Technology Container Corporation.

From Niche to Mainstream: The Evolution of Sleeve Packs

Sleeve packs have existed in the market for decades, but their adoption has seen a notable shift over time. Shuert traced their origins, highlighting how his company was at the forefront of the movement.

“Our company developed and patented the first twin-sheet sleeve pack back in 1982,” he explained. “It was originally developed with a corrugate sleeve and was relatively successful in North America, primarily in the textile industry. But it really took off in Europe, where companies like Ford of Europe used them as a substitute for metal cages.”

The transition to plastic sleeves was a turning point, allowing for greater durability and reuse. “It wasn’t until the last 10 or 15 years that we started seeing real traction here in North America,” he said. “If you walk around the hall today, you’ll see more sleeve packs in booths than collapsible bulk boxes. That’s been a real, real change over the last three or four years.”

Kamholz reinforced this point. “What Matt is saying is 100% true,” he said. “The transition to a flexible sleeve pack has grown immensely in North America.”

Why Sleeve Packs? Flexibility, Cost Savings, and Sustainability

Beyond durability, sleeve packs are being recognized for their unparalleled flexibility. Breitkreuz explained how companies can optimize them to suit various applications.

“One of the biggest benefits of a sleeve pack, compared to a classic folding large container (FLC), is customization,” he said. “You have flexibility in height, drop doors, weight, and how the sleeves are cut.”

Breitkreuz cited Volkswagen as an early adopter. “Volkswagen made the shift from steel to sleeve packs for all their lightweight and interior parts,” he said. “They now have at least 500,000 sleeve packs in their logistics network. That trend has opened doors in every industry.”

Carpio, whose company is pioneering sleeve production in Mexico, noted that customization goes beyond automotive applications. “We’re seeing strong opportunities in automotive and retail, but also in food,” he said. “We recently developed a hexagonal sleeve pack for a major company to use with pasta.”

Cost savings also play a significant role in the shift toward sleeve packs. Breitkreuz emphasized that their return on investment (ROI) is often achieved in six months to a year due to reduced freight costs and increased stacking efficiency.

Durability and the Push Toward Lighter Materials

Durability is another key factor in sleeve pack adoption. Based on experience with longtime sleeve pack users such as Vokswagen, Breitkreuz has found a six-to-seven year service life to be typical.

“I can tell you, after doing this for 38 years, that I’ve been in customers’ plants in the last couple of years where I’ve seen product that goes back to the 90s,” Shuert added. “It’s all about how you use them and how you handle them.”

Carpio told the group that his company repairs damaged sleeve packs so that customers can get an additional two or three years of service.

Delorey noted a trend toward lighter materials which still maintain strength while reducing costs and improving sustainability. “Originally, most of the sleeves were 10mm, heavy-duty gauges. Now we’re seeing more requests for shroud sleeves, something that covers components rather than acting as a rigid container,” he said.

Shuert expanded on this idea, explaining how material reductions contribute to sustainability.

“There’s no reason a sleeve has to be 3000 grams if it can be 2000 grams,” he said. “Same with pallets and tops. The less material you use, the more environmentally friendly it is. We’re not here to bad-mouth bulk bins, but when you look at weight and freight costs, sleeve packs can make sense.” Shuert noted that each product has use cases where it excels.

Challenges in Standardization

A key discussion point at the panel was whether sleeve packs should have standardized dimensions. Some industries, such as beverage, have successfully standardized secondary packaging like layer pads, allowing for more efficient return logistics. However, sleeve packs remain highly customized.

“I can tell you, 99% of the sleeve packs I’ve sold were not standard,” said Breitkreuz. “Customers prioritize optimizing load capacity and pack density over fitting into a universal system.”

Shuert shared an example of a company attempting to standardize sleeve pack sizes for sea shipments.

“We had a customer that developed a sleeve pack for pooling that fit perfectly into a sea container,” he said. “It wasn’t very successful. Every country has its own way of doing things, its own standards, and infrastructures. That made it difficult to get traction.”

Kamholz acknowledged the appeal of standardization but questioned its feasibility.

“At Cabka, we see ourselves as solution providers,” he said. “Every customer has unique needs, and we pride ourselves on meeting those needs rather than forcing a one-size-fits-all solution. Standardization sounds great in theory, but in reality, it’s tough to implement.”

The Future of Sleeve Packs

With continued emphasis on customization, cost savings, and sustainability, sleeve packs are poised to further displace traditional bulk packaging solutions such as gaylords. Carpio highlighted another advantage: tracking and traceability.

“Plastic sleeves allow for integration of RFID and barcode scanning, which optimizes supply chain visibility,” he said.

Despite challenges in standardization, the industry agrees on one thing: sleeve packs are here to stay. Their adaptability, lightweight design, and sustainability benefits make them a compelling choice for industries looking to improve their bulk packaging solutions.

As Breitkreuz put it: “If you have a challenge, let us know. Sleeve packs might just be the answer.”

Reference: https://packagingrevolution.net/sleeve-packs-customization-sustainability/