Case Study: How Pregis Transformed Packaging Damage Into Measurable Operational and Sustainability Gains

After implementation, the numbers confirmed the assessment that AirSpeed^® ChamberPak^® would deliver measurable value across the operation.

By preventing damage reships, it significantly reduced the environmental impact and costs associated with damaged products. It led to a 74% decrease in emissions and a 66% decrease in landfill waste.

Challenge:

A leading plumbing-supply and home-fixture distributor using a competitor's foam-in-place packaging system was seeing rising damage rates. The distributor needed a new packaging approach that could reliably protect heavy, fragile fixtures.

Assessment:

During an onsite assessment, Pregis uncovered the incumbent solution was taking up valuable floorspace and slowing throughput. However, initially concerned with prioritizing recyclability, the customer opted to try a paper solution first.

When it became clear that the paper solution was failing to address the damage issues, the Pregis sales team helped communicate the impact of product damages on the environment and leveraged the Pregis IQ® to validate how effectively AirSpeed® ChamberPak® could protect the heavy, fragile products through real-world ship testing.

Solution:

On paper, ChamberPak was a perfect fit. Its nylon barrier maintains air pressure and long-term cushioning performance. Additionally, its patented one-way valves ensure that if one chamber is compromised, the rest remain fully inflated. All of this comes with a compact design and simple one-step process, reducing pack time.

Together, these features led to decreased damage rates, consistent protection, reduced warehouse space and simplified operations.

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