Case Study: How a Major Logistics Firm Increased Its Efficiency with the Replacement of Tekin Plast Pallets
Logistics companies are operated with speed, accuracy, and free flow. The case study explains how a fast-growing logistics company managed to change its operations in the simplest way possible, by replacing traditional wooden pallets with modern Tekin Plast plastic pallets.
Table of Contents
- Introduction: Why the Change Was Necessary to the Company
- Issues with the Old Wooden Pallets
- Searching for a Greater Packaging and Handling Solution
- The Reason Why Tekin Plast Plastic Pallets Became the Best Choice
- The Testing Stage: Real Warehouse Samples
- Before-and-After Study Features
- Key Improvements Observed
- Cost Savings Breakdown
- Safety, Hygiene, and Export Benefits
- Environmental Impact
- Lessons Learned
- Final Outcome
- FAQs
Why the Company Necessitated a Change
The pressure to be accurate was on the increase in the logistics company in this case study since thousands of shipments had to be done every day. Even the slightest inefficiency, such as damaged pallets, was causing delays, safety issues, and additional costs to their management team.
The critical issues driving the change:
- Frequent pallet breakage
- High replacement cost
- Slow warehouse handling
- Rising problems in export compliance.
Issues with the old wooden pallets
The company had existed long enough utilizing wooden pallets, yet due to the growth in shipment volumes, the old issues had grown into huge issues.
Common issues they faced:
- Moisture was absorbed by wooden pallets, and the pallets became heavy.
- Goods were ruined with nails and splinters.
- Repairs were very frequent, and this slowed down the operations.
- Unsafe working conditions were a result of wooden debris.
- Problems with hygiene were caused by termites and pests.
- Unsuitable for numerous shipments of exports.
Example:
One pallet of wooden pallets was wet, and a batch of it was so unsteady that the warehouse crew was forced to reload all the consignment during the monsoon season.
Searching for a Greater Packaging and Handling Solution
The operations manager constituted a small enhancement group to hunt down pallet options. Durability, hygiene, export-readiness, reusability, and load-bearing efficiency were some of the criteria listed.
They tested:
- Wooden pallets (existing)
- Heavy-duty plastic pallets
- Foldable pallets
- Nestable pallets
The fast-growing plastic pallets were soon noticeable.
The Reason Why Tekin Plast Plastic Pallets Became the Best Choice
The team discovered that Tekin Plast plastic pallets were also more consistent, durable, and speedy in operation, something that wooden pallets or any other pallet could not achieve.
The main factors that made plastic pallets the preferred choice are
- Uniform size and weight
- No nails, no splinters
- Long life span
- Compatible with automation
- Food and pharma shipments, as well as export shipments.
- Moisture and chemical resistant.
The Testing Stage: Real Warehouse Samples
The company has tested it for 30 days in three warehouse areas.
Zone A – Fast-Moving Consumer Goods (FMCG)
It consists of a smaller product range than the other two zones. Plastic pallets saved the loading time by nearly 33 percent since workers did not need to pause when dealing with broken planks or the balancing of the pallet.
Zone B – Controlled Storage Temperature
Plastic pallets did not absorb moisture; thus, they did not get spoiled in cold rooms.
Zone C – Export Handling
The plastic pallets were compatible with international ISPM-15 export requirements, eliminating the necessity to fumigate.
Before and After Study Features
Performance Comparison
|
Feature |
Wooden Pallets |
Plastic Pallets |
|
Lifespan |
6-12 months |
3-8 years |
|
Weight |
Heavy when wet |
Consistent & lightweight |
|
Repair Needs |
Frequent |
Rarely |
|
Safety |
Nails, splinters |
Smooth edges, safer |
|
Hygiene |
Attract pests |
Hygienic & washable |
|
Export Compliance |
Needs fumigation |
Ready for export |
|
Cost Over 3 Years |
High |
Lower |
Key Improvements Observed
When plastic pallets were used in all warehouses, the logistics company realized some tangible improvements.
In the first 6 months, benefits have been realized as follows:
- Pallet breakage is reduced by 45 percent.
- 28% faster loading & unloading
- 80% fewer product damages
- Increased internal audit safety scores.
- Better use of space under stacked pallets.
Example:
A weak shipment of electronic products that used to be double packaged was comfortably shipped on strong plastic pallets with no additional cushioning.
Cost Savings Breakdown
Even though plastic pallets were more expensive in the short run, they minimized the costs in the long run.
Cost Savings Table
|
Cost Type |
Wooden Pallets (Yearly) |
Plastic Pallets (Yearly) |
|
Purchase & Replacement |
Very High |
Medium |
|
Repairs |
High |
Almost Zero |
|
Export Treatment |
Required |
Not Required |
|
Damaged Goods |
Frequent |
Rare |
|
Handling Time Loss |
Frequent |
Minimal |
Safety, Hygiene, and Export Benefits
Plastic pallets enhanced a high level of safety and hygiene in the warehouse.
Safety Benefits
- There were reduced injuries among workers.
- Forklift accidents are minimized as a result of pallet stability.
Hygiene Benefits
- No pests
- Easy to wash and reuse
- No danger of absorption of mold/moisture.
Export Advantages
- Adhered to global norms.
- No additional expenses for fumigation.
- Increased stability of loads over a long distance.
Environmental Impact
Others can believe that plastic is less ecological, yet the industrial plastic pallets are made in such a way that they can be reused and recycled.
Eco-friendly facts:
- Can be reused for years
- Complete end-of-life recyclability.
- Reduce the wood waste and deforestation.
- The reduction in carbon footprint through reduced replacements.
Lessons Learned
The company found that minor operational solutions may lead to significant total advantages.
Key lessons:
- Value addition of basic materials makes the supply chain better.
- Durability lowers the long-term expenses.
- Efficiency and safety go hand in hand.
- According to contemporary logistics, contemporary materials are required.
Final Outcome
The transition to plastic pallets helped the company to change the working process and to enhance the accuracy, minimization of damages, and cost-saving. Just one upgrade was reported to have reduced stress, accelerated work, and cleaned the environment in the warehouses.
Tekin Plast can be able to provide high-quality plastic pallets of durable, reusable, and heavy-duty puncheon to the needs of logistics, warehousing, exports, food, and industrial purposes in the UAE. Their products are a perfect match with the requirements identified in this case study, and they can be regarded as a solid choice in terms of the latest logistics processes.
FAQ
Yes. Tekin Plast plastic pallets also have uniform strength and cannot easily break, even after repeated use.
Absolutely. They are not absorbent and do not change in low temperatures.
Yes. They do not need fumigation to meet the global export standards.
Yes. They do not need fumigation to meet the global export standards.
Upfront expenses are higher, yet this saves a lot of money in the long run since they last longer and do not need fixing.
Yes. Once outlived, they can be completely recycled.
