Gearbox consolidation pack

A British design and manufacturing company based in Aberdeenshire, Scotland contact the team to develop a specialised packaging solution for two of their gearbox models.

These precision-engineered units required a robust and highly secure packaging system capable of withstanding the demands of shipping and transportation.

A key challenge was that the two gearboxes differed in size, yet the solution needed to use the same outer box and internal fitting system for both models.

We engineered a versatile packaging design that accommodated both units securely within a single standardised pack format. This approach improved efficiency in packing, storage, and logistics while maintaining a high level of protection.

The solution we developed utilised a single standard fitting design incorporating a tear-away section. This feature allowed the customer to remove a designated portion of the fitting, enabling the same pack format to securely accommodate the alternative gearbox size.

The internal fitting was constructed from four protective panels, providing robust side protection on all faces. Together, these panels formed a central aperture that held the gearbox firmly in position, preventing movement during transit while absorbing impact and handling stresses.

• Secure transit – Heavy gearboxes stabilised and protected throughout shipment
• Reduced material usage – Optimised structural design without over-packaging
• Tooling cost savings – One fitting design instead of two
• Lower overall packaging cost – Direct financial benefit to the customer