Depending on the container size, at least two crossbars are fitted into opposing side walls using purpose-designed, patented plastic holders. A structured-core panel is then laid on top to create a high-load intermediate level.
“With this addition to our range, we are addressing our customers’ needs in a targeted way. By allowing large load carriers to be subdivided horizontally using free-floating intermediate layers, we help customers use resources more efficiently, optimise logistics processes and provide a smart solution for modern supply chains,” says Florian Herkenrath, Project Manager at the WALTHER Faltbox Group.
Our design engineer Stephan Engelhardt explains what mattered most during development: “As with all our products, we placed strong emphasis on sustainability, user-friendly handling and durability. We designed the solution to work across different sizes, so it can be used with a wide range of large load carriers. What’s more, once the crossbars are removed, the containers can still be folded down to save space.”
Load testing for the new intermediate layer
To reliably verify the loads our new system can withstand, we commission independent experts at the VDZ GmbH Kompetenz- und Prüfzentrum für Verpackung und Transport in Dortmund to review our development. The new solution underwent both static and dynamic load tests under a range of temperature conditions. These external tests provide objective evaluations, identify potential improvements and ensure our products meet the highest industry standards.
We test every new development under operational conditions to ensure it meets practical requirements. We have supported WALTHER for many years with objective, reliable test results, helping to continuously improve newly developed products.
Benefits of the intermediate layer
The ability to subdivide large load carriers into horizontal levels delivers a range of benefits – including more efficient space utilisation, greater logistics flexibility and improved product protection during transport. Here are the key benefits of our solution at a glance:
- Better space utilisation: The additional level allows the available footprint to be used more efficiently.
- Improved load protection: Products don’t have to be stacked directly on top of one another. The free-floating intermediate layer separates them, so the lower items aren’t subjected to top loads, which helps protect sensitive products.
- More flexible order picking: An intermediate level enables different product groups to be transported separately, speeding up downstream handling. It also makes partial picking much easier, as the entire load carrier doesn’t need to be unloaded.
- More efficient transport logistics: A large container with an intermediate level is ideal for just-in-time supply chains, since multiple components can be delivered in a single load carrier.
- Cost savings: Flexible use of intermediate levels to consolidate product groups more effectively can reduce the required size of the load carrier pool.
- Sustainable reusable system: Large load carriers with an intermediate level are reusable, helping to conserve resources.
- Space-saving returns: After the crossbars have been removed from the container, it can be folded as usual. The volume reduction enables return transport to be organised as efficiently as possible.
