Packaging StandardsIntroductionThis section of the manual outlines SAMS Club packaging standards.These stan-dards are designed to assure that merchandise is properly supported and protected during shipping and handling. It is imperative that during the buying process vendors clearly understand our packaging requirements. Failure to meet these requirements may result in fines, and / or charges to the vendor.Following these packaging specifications does not relieve our vendors of liability in the event that packaging is defective, or for any reason fails to protect merchandise dur-ing shipment. It should be standard practice that vendors be given a copy of these specifications, and that they read and understand these standards.AdvantagesLower Returns:Defective packaging significantly contributes to customer returns, and loss of customer confidence in our merchandise, which directly relates to our profitability.Cost Effective Packaging:Following these packaging specifications will help you negotiate more effectively for quality packaging at the best possible cost.Vendor Relations:The majority of our vendors will want to comply with our specifica-tions as outlined. During finalization with vendors let them know that you are taking a personal interest in these matters and expect that they will comply with these stan-dards as outlined. It will be to their advantage to do so, as our volumes make SAMS Club a preferred customer.If you have questions, or are in need of additional information regarding packaging standards or graphics, contact:Wal-Mart Package Design708 S.W. “F” St.Bentonville, AR 72716-9127ph (501) 273-4407fx (501 273-8175email mrhill@ pg 1Packaging StandardsCorrugated Master Carton Standards1)Standard Master Carton should be made of B/C or A/C corrugated doublewall. Master cartons for K/D furniture will use a “Full Telescoping box constructed of not less than a “C” flute corrugated depending on total weight”. For description of fluting see page 8.2)Minimum corrugated medium weight 30# (147 grams per square meter) Semi Chem, or recycled concora value with a minimum 75 CMT. A poor quality medium will result in “soft” board. “Soft” board will result in lower stacking performance and reduce cushioning protection for product. Increasing the linerboard weight will help, but is not the most cost effective method. Increasing the medium per-formance is the desirable method of achieving better stacking performance. The fluting or medium is comparable to a bridge support structure; weaken the flute and the box (bridge) will collapse.3) Master Cartons must follow liner weights and box burst tests indicated in Rail Rule 41(See graph pg. 7). Master Carton inner and outer linerboards must use Kraft or Sulfate process using primarily soft woods, ie U.S. grade materials. This type of liner has long fibers and yields a much stronger material. Materials derived from grasses or woody plants high in recycled content are notvacceptable as they have short fibers and poor performance.4)Master Cartons must be customized to support merchandise. Voids greater than 1/4” are not per-mitted. Internal packaging must be used to fill these voids and to support the merchandise.5)Delicately finished merchandise such as furniture, appliances, hand painted items etc., must be protected from abrasive corrugated. Corrugated surfaces which come in contact with this type of merchandise must be coated with a non abrasive coating, or protected by other means, such as polyethylene wrap, sheet foam, etc.6)Glass or ceramic products are very susceptible to damage during transportation and handling. It isrequired that individual cells be used to protect fragile merchandise from impact damage during han-dling and transportation. Exceptionally fragile items may require additional protection, i.e. foam cush-ioning or bubblewrap.7) Master Carton Closure: Flaps should be glued with a water resistant adhesive applied to the “entire area of contact between flaps”. Running glue in narrow lines along the length of the flaps is not acceptable. For further protection all seams should be sealed with a water resistant tape. If mer-chandise is heavy this tape should be one with reinforcing fibers. No raw edges should be exposed that can catch on warehouse conveyers.8)All master cartons are required to bear a box certificate, shipping mark and handling symbols.pg 2Sam's Master Carton Test Reportpg2Material StandardsLinerboard & MediumIt is a standard practice on import merchandise that (GSM) weight of corrugated liners and mediums be upgraded to improver overall structural weakness due to raw materials used. U.S. grades, or equivalents almost always out perform locally produced liners and mediums, but the argument may be that U.S. or equivalent grade liners and mediums are more expensive.It is a fact that locally produced materials are less expensive than U.S. or equivalents grades based on comparable GSM weight, but the GSM on U.S. or equivalent grades far out-performs local in comparable weights. This results in a price that should be comparable, to just slightly higher, using a U.S. or equivalent with a much wider band of performance at a lesser GSM.Inspection ProceduresBoxes should be inspected for caliper and flute structure. This is easily checked by using a sharp knife (razor) and cutting a 4” square from each panel. Take each sample and cut a straight line across the fluting. Cut into the flute but not through it, and gently bend the board back and examine the flute construction.The flute should resemble a bell shaped curve as seen in example 1. The flute tips should be round-ed and not flat. If fluting is flat it has been crushed during manufacturing, or conversion. The flutes should be straight and not leaning. If leaning (see example 2), the corrugated flute structure has been weakened and will not support a load as it should. Any of the conditions listed above yields an unacceptable master carton.Example 1Example 2pg 3Materials and Design ConsiderationWhen master cartons are loaded into containers, they are stacked to the highest possible level with-in the container to make maximum use of space available. In doing so, the bottom boxes within the container are subjected to a great deal of environmental conditions, as well as static weight and duration of shipment, i.e. 30 to 45 days. These conditions must be considered during master carton design and materials needed on top of the “Minimum Performance” figures as outlined above in example.When the Master Carton is used as Display Carton the following table is to be used ( These standards are slightly higher than PDQ display).Max Loading Max. Girth Bursting StrengthWeight L+ W + HKG LB CM Inch KGF/Square CM LBF/Square Inch9.120101.640.012.3175.018.240152.460.014.0200.029.565190.575.019.3275.041.090228.590.024.9350.054.0120254.0100.035.0500.064.0140279.4110.042.0600.0Example: Master Carton & Contents = 26KG (57lbs) and measures 100CM(L) x 60CM(W) x45CM(H).1) The correct Max. Loading for this item is 26KG which exceeds the 18.2 column Max. Loading. Always move to the next higher number column for the correct value. (29.5)2) Total girth of current Master Carton = 205CM. Note that this total moves to the next higher column as it exceeds the max.190.5CM scale.3) The correct Burst Strength should be 24.9 KGF/Square CM or 350.0 LBF/Square Inch. Refer to illustration on page 5 for more information regarding this item.pg 4(A/C) Corrugate Doubler This doubler is placed inside the box between merchandise and outerbox. Fluting must be insame direction as box.SAMS CAST IRON UMBRELLA STAND PACKAGINGDirection of corrugate fluting must be at 90 degree angle to box base as indicated below.Packaging materials (corrugate) must be at least 350 GSM doublewall (A/C). Materials must be at least "B" grade. "C" grade materials are not acceptable for liner boards (inner and outer).Corrugated Medium should be of "Good" quality as well, not high recycled content.Tape materials used must be a heavy fiber mesh and must be neatly applied. Tape mustoverlap box seams by 3" (76.2mm). When taping box, care must be taken to make sure that all box flaps butt finish to each other (no gap).Folded and stapled edge of box seam must be at least 1 1/2" (38mm) wide.Corrugate FluteDirectionDoublewallInternal Corrugated Doubler.(EPS) Extruded Polystyrene or "heavy corrugate build-up" must be used. Material used must beat least proportional to illustration below to properly support and protect merchandise as well as givegreater structural support to outer packaging.Direction of corrugated fluting must be at 90 degree angle to box length as indicated below.Outer packaging materials (corrugate) must be at least 300GSM doublewall (A/C). Materialsmust be at least "B" grade. "C" grade materials are not acceptable for liner boards(inner and outer) or for corrugated medium.Box flaps must be glued (100% of flap surface) and taped, no raw edges exposed.Tape materials used must be a heavy fiber mesh, and must be "neatly" applied. Tape must overlapbox edges by at least 1" (25.4mm).Folded and stapled edge of box seam must be at least 1 1/2" (38MM) wide.SAMS 11' DIA. WOODEN MARKET UMBRELLA PACKAGINGRAIL RULE #41GRAPHCorrugated Fiberboard BoxesCorrugated Caliper Specification in S.A.E. & Metric1) Allow .015 Cm less than normal for printed areas2) Where not specified, medium weight is 30# per Msf or 147 grams per square meterBOX AND CORRUGATED STACKING PERFORMANCE ( Dynamic Compression)Stacking PerformanceThere are many factors that must be taken into consideration for the optimum stacking performance of corrugated packaging. During the shipping process, stacking, handling and humidity conditions must be considered, as these elements will definitely affectthe condition of the corrugated box arriving at destination. Listed below is a formula that will help assist you to get the best possible performance for your corrugated packaging. Box Size (L x W x D) See Rail Rule 41 chart for minimum recommendations of corrugate linerboards and mediums to be used as a starting point for packaging.Note : Rail Rule 41 chart minimums are based on box and merchandise weight only.Iitems 4 through 7 are safety factors that "must " be considered to achieve optimum performance. Total weight per box (including merchandise)=_______lbs How high will it be loaded within the container (less bottom box). x_______Static weight on bottom box =_______SHIPPING SAFETY FACTORS (S/F)S/FHumidity: Dry..............................................Less than 50% -1 _______Normal Humidity.................................50 to 60% 0 _______High Humidity.....................................61 to 80%+1 _______Extremely High Humidity...................80 to 100%+2 _______S/FStorage Time...................................0 to 2 weeks 0 _______Storage Time...................................2 to 4 weeks +1 _______Storage Time.........................More than 4 weeks +2 _______Does merchandise aid in supporting load:S/FExtremely supportive (Cans or Glass)-2 _______Somewhat supportive (Folding Cartons in RSC)-1 _______Not Supportive (Clothing, Soft goods) +1 _______Must be supported (Bulk Items, Fragile)+2 _______An additional safety factor must be calculated for road transportation (trucking) of merchandise once landed, as well as handling during this process. If weight per box is less than 40lbs (18.14KG calculate an additional 1.5 S/F, or if over 40lbs (18.14), calculate 2 S/F. ________ Safety Factor total from items 4 thru 7 =________ Static weight on bottom box (item 3) x________ Total Dynamic Compression =________1234567STANDARD PALLET SPECIFICATIONSACCEPTABLE(SEE PALLET SPECIFICATION ON PAGE THREE)PALLET SPECIFICATIONSPallet StackingWhen designing displays it is important the actual pallet style/design is taken into consideration. Spacing between the slats can be a real challenge as box structural integrity can be compromised when box corners fall between the slats and results in box failure at those locations. (See Illustration below)1) Reconfigure merchandise on pallet2) Use a rigged corrugated barrier sheet between boxes and pallet3) Use a corrugated pallet (with flat stacking surface)Master Carton / PDQ Stacking1) Columnar Stacking: The best stacking arrangement for box compression strength is vertical columns. (See Figure #1)When stacking in columnar as shown in figure #1, care must be taken to insure that boxes are properly aligned. In a three stack arrangement (figure #1), if boxes are misaligned as little as 1/2" (1.27cm), loss of stacking compression performance will drop by as much as 29%.2) Interlock Stacking: This type of stacking affords a much more stable platform than does columnar stacking. As each layer is arranged in opposing directions. Although this type of stacking is more stable it drastically affects the stacking compression performance of the containers. The corners of the container do not align on all four corners of thecontainer; in fact three of the four sides rest on the side panel of container below. The result of this type stacking is a 45% to 55% loss in compression strength.Never stack containers where the sides are overhanging the pallet, as two thirds of the overall compression strength of the container is based on the four corner support of the container. Example, a 1" overhang (2.54cm)will result in a 32% or more loss in top to bottom compression of the container.Figure #1ColumnarStackingthe edge of the pallet.Incorrect Displayers Displayers shown are poor presentationsto the customers.1) Displayers should be in "White" trays.2) Displayer should be in trays with rolled edges.3) Product information should be on outsideof the displayer on front and side panels.4) Packaging information and photography should be able to be viewed by the customer within the displayer unit.5) Displayers shown should be in telescoping type units.Correct DisplayersDisplayers shown are good presentationsto the customers.1) Displayers in "White" trays.2) Displayer in trays with rolled edges, and packaging designed to withstand long term stacking.3) Product information on outside of thedisplayer on front and side panels.4) Packaging information, and photographyshould be able to be viewed by the customer within the displaye unit.5) Note: Displayer shown at bottom right has upper section arranged where packaging ends and face panel are in plain view to the customer.telescoping box lid to base by using a "cold"glue on all four sides of the box base "before"banding.must be applied in heavy coats.Do not use narrow strips for gluing lids.Narrow strips of glue do not adequately bond the two surfaces together and will,in most cases,fail during shipment or in transportation to our clubs.Banding must not cover information or graphics on Tension on banding must be tight enough to hold corrugated lid in place without damaging packaging.carton size must be considered during packaging design as it will be displayed in our club using a48"X 40"pallet size.Merchandise cannot hang over the edge,or have excessive space when palletized for display.packaging is critical for furniture,and on fragile or heavy items.It is highly recommended that apackaging engineer be consulted on this type merchandise for best possible performance.All Master carton must have all raw edges taped as indicated in the "Import Packaging Standards" item #6.is too tight,boxbe damaged,and structural integrity INCORRECTCORRECTFurniture Packaging,Stacking & BandingPALLET DISPLAYS¥Maxiumum height for a pallet display is 52"including the pallet base.¥Minimum height for a pallet display is 50"including the pallet base.i r B e di r B e d A i r BeDisplay TrayThis type of Displayer is designed to be pulled from the shipper carton and placed onto the shelf. This design is primarily for boxed merchandise, but can also be used with carded merchandise or cylinder shapes. The buyer or the modular planner must advise the vendor or PREL Agent as to the location for the display and the shelf area available. Minimum material weight = 200 lbs burst strength "B" Flute Corrugated.Vendors must properly load and mark the shipping carton showing correct orientation to prevent spillage at store.1) All PDQ shipper cartons are to be marked with arrows indicating correct orientation for shipping and handling as noted in illustration.2) All PDQ shipper cartons are to indicate correct opening procedures, i.e. "open this end" as noted in illustration.Flip Top DisplayerTop Displayer's are designed for self erecting and gravity feed.This type of displayallows store associates to open and place the displayer in its location,and merchandise self feed to the front.This type of displayer can be used for boxed,carded,cylinder merchandise.adhesive label used for product information and price point.Vendors must properly load and mark the shipping carton showing correct orientation to prevent spillage at store.1) All PDQ shipper cartons are to be marked with arrows indicating correct orientation for shipping and handling.pg20NOTE: Sleeve closure on this type of display tray it is required to be attached by one of two means, banding or a heavy caliper polyethylene wrap across the length.Standard Display TrayVendors must properly load and mark the shipping carton showing correct orientation to prevent spillage at store.1) All PDQ shipper cartons are to be marked with arrows indicating correct orientation for shipping and handling as noted in illustration.2) All PDQ shipper cartons are to indicatecorrect opening procedures, i.e. "open this end"as noted in illustration.The front panel of the displayer can be printed orlabeled for merchandise information, and or price point.The type Displayer is designed to be pulled from the shipper carton and placed ontothe shelf or pallet display. This design is primarily for boxed merchandise but can also be used with carded merchandise or cylinder shapes.Minimum material weight = 200 lbs burst strength "B" Flute Corrugated.CSTACKABLE DISPLAYERS1) When stack pack displayers are used it is mandatory for the four vertical corners to be reinforced with a paper board or corrugated doublers. ( See illustration 1 for correct design), (Illustration 2 for incorrect design)2) Corrugated flutes must be designed where they are perpendicular to the base of the display unit.Minimum material weight = 200 lbs burst strength "B" Corrugated + reinforcementat corners.Vendors must properly load and markthe shipping carton showing correct orientation to prevent spillage at store.1) All PDQ shipper cartons are to be marked with arrows indicating correct orientation for shipping and handling as noted in illustration.2) All PDQ shipper cartons are to indicatecorrect opening procedures, i.e. "open this end"as noted in illustration.Version #1Telescoping LidVersion #2Klean Cut with Elephant ear(Illustration 1)Standard Display TrayThe type of Displayer is designed to be pulled from the shipper carton and placed onto the shelf or built as a stackable tray. If the tray is used for a stacking display, the load weight the displayer is to hold is critical. Light weight items are better suited for this type of displayer when stacking.Minimum material weight = 200lbs burst strength "B" Flute Corrugated.the shipping carton showing correct orientation to prevent spillage at store.1) All PDQ shipper cartons are to be marked with arrows indicating correct orientation for shipping and handling as noted in illustration.2) All PDQ shipper cartons are to indicate correct opening procedures, i.e. "open this end" as noted in illustration.Standard Display TrayThis type of Displayer is designed to be pulled from the shipper carton and placed onto the shelf, or built as a stackable tray. If the tray is used for a stacking display the loaded weight the displayer is to hold is critical. Light weight items are better suited for this type of displayer when stacking, unless actual merchandise can share a portion on the load.Minimum material weight = 200 lbs burst strength "B" Flute Corrugated.Vendors must properly load and mark the shipping carton showing correct orientation to prevent spillage at store.1) All PDQ shipper cartons are to be marked with arrows indicating correct orientation for shipping and handling as noted in illustration.2) All PDQ shipper cartons are to indicatecorrect opening procedures, i.e. "open this end"as noted in illustration.Shelf DisplayerStacked DIsplayDisplay TrayVendors must properly load and mark the shipping carton showing correct orientation to prevent spillage at store.1) All PDQ shipper cartons are to be marked with arrows indicating correct orientation for shipping and handling as noted in illustration.2) All PDQ shipper cartons are to indicatecorrect opening procedures, i.e. "open this end"as noted in illustration.Shelf DisplayerThis type Displayer is designed to be removed from the shipper carton and placed onto the shelf. This design is primarily for boxed merchandise, but can also be used with carded merchandise or cylinder shapes.Minimum material weight = 200 lbs burst strength "B" Flute Corrugated.Cargo Container LoadingStacking Directly on top of lower corrugated box is the preferred method. Vertical positioning ofcorrugated flutes provides best support for stacking.Voids must be kept to the center of the container and dunnage materials used to tightly hold master cartons. Shifting of master cartons during sea travel must be kept to an absolute minimum to insure goodsarrive in the best possible condition.Flute Direction should be indicated on the outside of master carton as shown in illustration.Carton Shipping & Handling SymbolsThe exterior of the master cartons should be marked with the applicable symbols. These symbols will assist the shipper in determining proper handling necessary for master carton and contents to arrive at destination in good condition.Hand truck hereUse no hooks Stack heightMaster Carton CloserBOX AND CORRUGATED STACKING PERFORMANCE ( Dynamic Compression)Calculating Stacking PerformanceExample: Cast Iron Patio Umbrella Stand weighs 65lbs, measurements are 24" x 24" x 3 1/2".Box size is 24 1/2" x 24 1/2 x 4 1/4". Merchandise weight, stacking height and duration of shipment are major factors with this item. Stacking height within the container is 102", or 2.59 meters. 102" divided by 4 1/4" equals 24 boxes that can be stacked within the container. Box Size (L x W x D) See Rail Rule 41 chart for minimum recommendations of corrugate linerboards and mediums to be used as a starting point for packaging. Note : Rail Rule 41 chart minimums are based on box and merchandise weight only. Items 4 through 7 are safety factors that "must " be considered to achieve optimum performance during shipment.Total weight per box (including merchandise) =_______ How high will it be loaded within the container (Less bottom box) x_______Static weight on bottom box (Loaded on Container or Trailer) = _______SAFETY FACTORSS/FHumidity: Dry..............................................Less than 50% -1 _______Normal Humidity.................................50 to 60% 0 _______High Humidity.....................................61 to 80% +1 _______Extremely High Humidity...................80 to 100% +2 _______S/FStorage Time...................................0 to 2 weeks 0 _______ Storage Time...................................2 to 4 weeks +1 _______Storage Time.........................More than 4 weeks +2 _______ Does Merchandise aid in supporting loadS/FExtremely supportive (Cans or Glass) -2 _______Somewhat supportive (Folding Cartons in RSC) -1 _______Not Supportive (Clothing, Soft goods)+1 _______ Must be supported (Bulk Items, Fragile)+2 _______An additional safety factor must be calculated for road transportation (trucking) of merchandise once landed, as well as handling during this process. If weight per box is less than 40lbs(18.14)calculate an additional 1.5 S/F, or if over 40lbs, calculate 2 S/F. S/F ________Safety Factor total from items 4 thru 7 =________Static weight (Total item 3) x________Total Dynamic Compression=________65 lbs (29.36KG)23+1+2-1+4+21495 lbs (678.32KG)1495 lbs (678.32KG)5980 lbs (2712.52KG)(EXAMPLE)1 234567BOX AND CORRUGATED STACKING PERFORMANCE ( Dynamic Compression)(Summary)The purpose of this calculation is to evaluate the forces acting against the container i.e. stacking strength, handling and environmental conditions that will affect final condition of packaging, and ultimate presentation to our customers.Static Weight: This is the total weight exerted against the bottom box when stacked into the container or trailer. (total of items 2 x 3)Safety Factors : These are conditions that "will" affect the compression strength of the corrugated materials, i.e. Humidity, Time Under Compression, Shipping and Handling. (total of items 4 thru 7)Total Dynamic Compression: The sum of all factors acting against the the corrugated container. Corrugated materials used, and box design must be adjusted to support this weight factor (Dynamic Compression). (total calculation of items 1 thru 7)Calculating Stacking PerformanceExample: Cast Iron Patio Umbrella Stand weighs 65lbs, measurements are 24" x 24" x 3 1/2".Box size is 24 1/2" x 24 1/2 x 4 1/4". Merchandise weight, stacking height and duration of shipment are major factors with this item. Stacking height within the container is 102", or 2.59 meters. 102" divided by 4 1/4" equals 24 boxes that can be stacked within the container. Box Size ( L x W x D) See Rail Rule 41 chart for minimum recommendations of corrugate linerboards and mediums to be used as a starting point for packaging. Note : Rail Rule 41 chart minimums are based on box and merchandise weight only. Items 4 through 7 are safety factors that "must " be considered to achieve optimum performance during shipment.Total weight per box (including merchandise) =_______ How high will it be loaded within the container (Less bottom box) x_______ Static weight on bottom box (Loaded on Container or Trailer) = _______ SAFETY FACTORSS/FHumidity: Dry..............................................Less than 50% -1 _______Normal Humidity.................................50 to 60% 0 _______High Humidity.....................................61 to 80% +1 _______Extremely High Humidity...................80 to 100% +2 _______S/FStorage Time...................................0 to 2 weeks 0 _______ Storage Time...................................2 to 4 weeks +1 _______Storage Time.........................More than 4 weeks +2 _______ Does Merchandise aid in supporting loadS/FExtremely supportive (Cans or Glass) -2 _______ Somewhat supportive (Folding Cartons in RSC) -1 _______ Not Supportive (Clothing, Soft goods)+1 _______ Must be supported (Bulk Items, Fragile)+2 _______An additional safety factor must be calculated for road transportation (trucking) of merchandise once landed, as well as handling during this process. If weight per box is less than 40lbs.calculate an additional 1.5 S/F, or if over 40lbs calculate 2 S/F. S/F ________Safety Factor total from items 4 thru 7 =________Static weight (Total item 3) x________(678.13KG)Total Dynamic Compression=________65 lbs (29.48KG)23+1+2-1+4+21495 lbs (678.13KG)1495 lbs 5980 lbs (2712.52KG)(EXAMPLE)1 234567。