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P U S H / P U L L & S L I P S H E E T H A N D L I N G M A N U A L

Global Solutions in Materials Handling

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Table of Contents

PUSH/PULL & SLIPSHEET HANDLING MANUAL

■ INTRODUCTION BACKGROUND & REVIEW

What You May Not Know About Slipsheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Palletless Load Handling–Is It Your Future? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Put It On A Slipsheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Push/Pulls Global Progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Slipsheets: The Pallet’s Successor? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Are Packagers Ready For Slipsheets? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Making A Case For Slipsheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Slipsheets Save Weight And Cost In The Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Germany Says No To North American Pallets! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34US Tells Importers: Pests Are Unpalletable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36Freight Processing Centers: Logistics’ Missing Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

■ COST COMPARISONS

Slipsheets & Pallets: A Cost Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Why General Foods Converted To Slipsheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47Cost Comparison Worksheets (Examples and Blanks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Slipsheets vs. Pallets – The Decision Making Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

■ CASE HISTORIES & INDUSTRY UTILIZATION

Slipsheeting The World – Apple Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67Cascade Plays Key Role – Apple Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68Slipsheets Generate Hyper Savings – Apple Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70You Must Use Slipsheets – Home Depot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74Lift Truck Attachment Eliminates Pallet Use – Quaker State Oil . . . . . . . . . . . . . . . . . . . . . .79Prior To Slipsheets – Speech By Jim Chase, President Jewell Foods, Inc. . . . . . . . . . . . . . . .84Unitizing 30 Lb. Cans Saves 75% Labor – Pik'd Rite, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . .88On-The-Job Application Report – Simplot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89On-The-Job Application Report – Northern Fruit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94Industries Using Push/Pulls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

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■ CONVERTING TO SLIPSHEETS

Slipsheeting – From Team To Reality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101Slipsheeting – Making It A Success For Suppliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103Do’s & Don’ts Of Converting To Slipsheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111Recommended Guidelines To Follow For Successful Push/Pull Test . . . . . . . . . . . . . . . . . .114Slipsheet Specifications – Apple Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115Home Depot's Conversion Spurs Interest In Slipsheets . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

■ OTHER INFORMATION

Load Push/Pull Equipment & Operator Guide . . . . . . . . . . . . . . . . . . . . . . . . . .Cascade InsertU.S. Slipsheet Suppliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125Cascade Field Organization & Customer Support . . . . . . . . . . . . . . . . . . . . . . . .Cascade Insert

■ ELECTRONIC CUSTOMER SUPPORT

Brochures/Advertising Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cascade Insert

Table of Contents (cont.)

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Introduction Background & Review

PUSH/PULL &SLIPSHEET HANDLING MANUAL

The palletless handling of unitizedgoods through the use of slipsheetsand push/pulls can save money andreduce damage. This manual willprovide you with the informationyou need to assist you in decidingwhether the Cascade Push/PullHandling System would be anadvantageous and cost-effectivealternative to the use of traditionalpallets.

There are two main components atthe heart of the Cascade Push/PullHandling System:

1. A load push/pull attachmentmounted on the front of anlift truck.

2. The slipsheet used in thepush/pull handling system isa thin, corrugated, solid fiberor plastic sheet used in placeof the traditional pallet.

In the following sections, potentialusers of the push/pull handlingsystem will find helpful informationincluding magazine articlescollected over many years, casehistories, brochures, and slipsheetspecifications.

Specific application orsupportive data can beobtained by contactingCascade Corporation @

800-CASCADE (227-2233)

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Slipsheets

WHAT YOU MAY NOTKNOW ABOUT SLIPSHEETS

Applications for slipsheets aregrowing at a steady rate. Hasinformation about their savingsreached you yet?

By C. W. Ebeling

To the vast majority of shippers,wooden pallets are synonymous withunitized shipping and handling. Inrecent years, outside of an occasionalarticle in a trade magazine, littleinformation has been disseminatedabout the continued use of slipsheets.It is no wonder that a new generationof shippers and logistics managershas grown up not fully aware of whata slipsheet is, let alone why andwhere slipsheets are used as analternative unitized shipping method.

Meanwhile, new applications forslipsheets continue to appearworldwide. The manufacturers ofpaperboard slipsheets report steadilyincreasing annual sales of 10% ormore. Currently over 150 millionpaper slipsheets are producedannually. Further indication of theextensive use of the slipsheet methodcomes from the manufacturers of thehandling attachments. Approximately18,000 push/pull attachments are inoperation in the U.S. Of the top 100industrial corporations listed in the1991 Fortune 500 list, 33 were usingslipsheets somewhere in their logis-tics operations.

Slipsheets, like pallets, have theiradvantages and their disadvantages.Applications in either case are foundwhere the advantages outweigh thedisadvantages. The main advantagesfor slipsheets are:

Most slipsheets are made of light-weight paperboard, which averages adollar or less each unit-load. They

are cheap enough to be discardedafter each trip. The costs of tracking,recovering, and repair or disposal,which are characteristic of thereusable wooden pallets, are notrequired for slipsheets. In keepingwith present-day environmentalconcerns, the used sheets are easilyassimilated into the wastepaper mar-ket for recycling into new products.

The tare weight of a slipsheets istypically two to three pounds each or20 to 30 times less than the tareweight of wooden pallets in a carloador truckload shipment. The space itoccupies under a unit-load isinsignificant compared to the 10% ormore taken up by a typical pallet.Most net payloads of unitized productcan be increased 10% or more withslipsheets. Putting it another way, thesame amount of freight that requires100 semi-trailers for shipments onpallets can be shipped in 90 semi-trailers when unitized on slipsheets(see T&D, Feb. ‘92 Slipsheets SaveWeight and Cost in the Air, p.53).

Slipsheets can be used economicallyto provide a unitized loading andunloading method for lightweightproducts that cannot economically beshipped on pallets due to lightweighttransportation penalties.

The disadvantages of slipsheets areusually related to the cost and per-formance concerns of shippers incomparison to the pallet method.These are:

The cost of a lift truck push/pullattachment to handle slipsheets is$6,000 to $8,000 compared to about$400 for standard fork truck tines.

The lift truck operators requirespecial training to effectively operatethe push/pull attachments. The timerequired to become proficient in theoperation of the equipment is several

times that required for the fork/pallet method.

There is no low-cost lift vehicle forthe horizontal transport of slipsheetunit-loads that is the equivalent of theinexpensive low lift manual pallettruck or jack. Slipsheet loads can beplaced onto pallets for in-househandling, but the transfer process isanother cost to be justified.

APPLICATIONS

What then are the applications forslipsheets in which the advantagesoutweigh the drawbacks?

The earliest applications of the slip-sheet method took place in the mid1940’s, several years before thebeginning of unitized shipping in theU.S. The sheets were used to reducethe costs of long term storage of unit-loads on pallets for products such ascanned fruits. The inexpensive sheetsavoided huge investments in palletsfor the buildup of inventory duringthe short harvest seasons.

With palletized shipping expandingrapidly throughout the food industryin the 70’s, a number of large manu-facturers began converting to slip-sheets for their long haul shippingoperations to get out of the costly anddifficult-to-control pallet exchangeprogram. The problems of palletrepair and the sanitation of reusedpallets gave further impetus to themanufacturers’ changeover to slip-sheets. During the conversionprocess it was found that the thinlightweight slipsheets made higherdensity payloads in many shipmentspossible, which resulted in reducedtransportation costs.

In 1988 Apple Computer introducedslipsheets to the electronics industrywith the first ocean container ship-ments of cased computer parts from

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Slipsheets

overseas suppliers in the Far East andEurope. Pallets were unaffordable forocean container shipments due totheir cost along with the cube lossthat would reduce payloads.Consequently, the goods had to behand stacked case by case in theocean containers. The replacement ofthe hand-stack operations with lifttruck slipsheet loading and unloadingsaved the company millions of dollarsannually and speeded the turnaroundof ocean containers at the shippingdocks for improved utilization. (SeeT&D Presidential Issue, 88/89.)

In 1991, Micropolis, a computercompany with manufacturingfacilities in Singapore and Bangkok,eliminated pallets under loads ofcased computer peripherals thatwere shipped by air freight from theFar East to the U.S. and Europe. Theirprogram demonstrated the practicalityof the use of slipsheets for air freightand the economic benefits ofincreasing load densities in air freightshipments through the use of slip-sheets in place of pallets (see T&D,Feb. ‘92, p.53).

The semi-bulk container method ofshipping raw and in-process materialsand goods is still another growingapplication for the slipsheet method.

A semi-bulk container carries theequivalent of an entire pallet load ofsmaller containers. In 1982 GeneralFoods introduced the use of semi-bulk containers with built-in slipsheetbases for the transport of coffeepowders from supply locations inSouth America to coffee packagingplants in the U.S. The slipsheet methodincreased handling productivity morethan ten times that of the traditionalmethods of packaging and shippingcoffee powder. Today the slipsheetedsemi-bulk boxes are used for a widevariety of raw and in-process materialsfor long haul and international ship-ments (see T&D, April ‘93, BronzeAge Method Aids InternationalShipments, p. 53.)

The growth of home product and do-it-yourself consumer stores such asHome Depot, Walmart, and K Marthas in the 90’s generated new interestin the slipsheet method. These hugeretail stores have their own receivingdocks and may receive truckloadshipments from suppliers of a varietyof merchandise ranging fromplumbing, heating, and electricalsupplies to step ladders and paint.Trailers arriving at store docks withhand-stacked loads take hours tounload and tie up the limited dock

space. Pallet loads speed unloadingbut require the eventual disposal ofthousands of used wooden pallets.According to Matthew Pitts of HomeDepot, each pallet received at theirNortheast stores results in a disposalcost that averages $2.50 each.

To facilitate the unloading of slipsheetunit-loads at the store docks, HomeDepot developed a special batterypowered, push/pull equipped dockvehicle in cooperation with Raymondand Cascade corporations. HomeDepot is currently carrying out aprogram to encourage all of theirsuppliers to convert to theslipsheet method.

With growing interest in the costs,productivity, and environmentalconcerns associated with shippingmethods today, logistics professionalsshould take a serious look at theslipsheet method and the advantagesit may offer.

Home Depot developed this batterypowered, push/pull-equipped dockvehicle in cooperation with theRaymond and Cascade Corporationsto improve the unloading of slip-sheeted unit loads at its store docks.Home Depot has implemented a pro-gram encouraging all its suppliers toconvert to slipsheets.

As seen in . . .Transportation &Distribution

Copyright © 1993 byPenton Publishing, Inc.,Cleveland, Ohio 44114

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Palletless Load Handling

PALLETLESS LOADHANDLING –IS IT YOUR FUTURE?Handling costs are a major factorin any distribution system. However,they can be reduced with the use ofslipsheets instead of pallets. Forexample, in the US, a typical qualityfiber slipsheet once costing 50cents is now US$1.50; a good quali-ty wood pallet has risen from US$5to about US$15.00. Although thecost of both have tripled, the differ-ential cost has gone from US$4.50to US$13.50 per unit. This cost dif-ferential will

continue to increase in the sameratio as the cost of wood goes up.

The most noticeable benefits withpalletless handling of unitized loadsis the reduction of cubic spacerequired and a reduction in weight.It is possible to increase productstorage capacity in the warehouseby 10 per cent, often eliminatingthe need for new warehouse con-struction as product distributionrequirements increase. Space issaved due to higher stacking capa-bility, the elimination of pallet stor-age space, and reduced needs forracking. More space means moreproducts in the warehouse, trans-

lating directly into a more produc-tive operation.

Whether transporting by container,truck or rail, less weight equalsmore payload, for example:

■ A 40" x 48" grocery palletweighs between 65 and75lbs.compared with the neg-ligible amount for an equiva-lent slipsheet

■ For a truckload of 40 pallet-loads, the payload is reducedby about 3,000lbs.

■ For a rail car shipment of 56palletloads, 4,200lbs. can be saved.

It doesn’t take long to see thepotential savings palletless handlingcan provide in transport costs. Addto this the other savings mentionedin this article and it is easy to seehow those non-value-added costscan be translated into additionalcompany profits, or lower pricesto customers.

PROBLEMS WITH PALLETS

While palletized cargo handling isentrenched in the shipping and dis-tribution industry and has workedwell for several decades, manyproblems remain and some arebecoming more critical. A keyconcern today is the destruction of anatural resource to produce pallets.There is an enormous demand forlumber from the pallet industry;according to one estimate, 50 per-cent of all hardwood lumber is usedfor pallets; 6 percent of total lumberTraditional wooden pallets are an expen-sive, environmentally-unfriendly, space-consuming and relatively awkward wayof supporting goods for transportationand storage. US company, CascadeCorporation, presents the Push/Pull slip-sheet system – a low cost, smoother wayto deliver, store and receive unit loads

Figure 1: Slipsheet palletless handling system

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production in the US is consumed bypallet manufacturing. Roger Rij, ofthe Agricultural Research Service, USDepartment of Agriculture in Fresno,California, has been researchinganother disadvantage of pallets –dis-posal of the one-way softwood pal-lets. No matter whether these ship-ments are heading to terminal mar-kets or chain store operations, thoseon the receiving end are still facedwith the problem of disposing of thepallets. Rij notes that one-way palletsstill have to be broken down, thusadding to the cost. Slipsheets, on theother hand, are easily recycled andoffer the distinct advantage of being are-sellable item.

Converting to slipsheets offers manymore cost savings, the largest beingthe capital investment required forpallets – US$150,000 for a 10,000-pallet system versus US$15,000 foran equivalent slipsheet operation.Other savings include the expenseassociated with pallet repair, returnshipping, lost pallets, sorting ofpallets, bookkeeping of palletexchange, pallets returned that areinferior to those shipped, and dam-

age to product causedby broken pallets.

Slipsheets also offerthe distinct advantageof reduced workerinjuries when com-pared to wooden pal-lets. Manual handlingof wood pallets weigh-ing any where from 25to 65lbs. can causehand, arm, back and foot injuries.Splinters and nails can also betroublesome. Most of these prob-lems are eliminated when usingslipsheets and, since they take uponly 1-2 percent of the spacerequired by pallets, slipsheets canoften be stored indoors, where theystay cleaner and are protected fromthe elements.

The greatest source of warehousecontamination usually arrives onpallets – rodent droppings andinsect infestation as well as chemi-cals and residues from previouslycarried products. Since slipsheetsare flat and made of inert materi-als, they do not provide a mediumfor infestation or contamination.Slip-sheets also eliminate the firehazard associated with inside oroutside storage of a large amountof wood pallets.

PALLETLESS HANDLING—THE US EXPERIENCE

Food productsGeneral Foods, now part of KraftFoods, has experimented withpallets and slipsheets since 1962.During the following decade, theproblems with pallets were becom-ing obvious. The cost of new palletshad doubled as had the costs ofrepair. Few pallets lasted even a yearand cost per pallet trip was in the

area of $1.00 each. Industry effortsto control the quality of pallets in theexchange system were not proving tobe successful. Problems of sanitationincreased with general deteriorationof the pallets in the pool and dam-age to products caused by brokenboards and protruding nails becamecommon. With the onset of the ener-gy crisis and the demand for highutilization of transportation equip-ment, carriers realized that palletswere taking considerable space anddisplacing room for revenue pro-ducing payload.

General Foods had early concernsabout slipsheet use, but soon foundthat the obstacles were minor andsolutions existed for most prob-lems. An example was its concernfor high stacking on slipsheets onwarehouse floors. At the time, thecompany could not conceive grip-ping a sheet under a top load andpulling it onto an attachment with-out pulling the entire stack over. Asit turned out, it was not a problemonce workers had been properlytrained and slipsheet loads werestabilized. In time, the shrink orstretch film wrapping commonlyused today proved to be the mostefficient form of load stabilization.Special non-slip adhesives have alsobeen developed to allow cases to beeasily lifted from the slipsheet whileat the same time preventing sliding.

Figure 2: One problem–pallet storage

Figure 3: The system in use

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General Foods was also concernedabout the substantial capital invest-ment required in order to convertautomatic palletizers to slipsheetunitizing and to provide slipsheetattachments for the lift trucks. Insome cases it was necessary toreplace the lift-trucks that did nothave sufficient counterweightcapacity for installation of a slip-sheet attachment that weighed 750to 1,000 lbs. and still carry therequired payloads. The expenditureproved to be justified, however, bythe reduction in pallet costs and thebenefits from higher density storageand shipping of more products.

“Slipsheets... are easily recycledand offer the distinct advantageof being a re-sellable item”

In addition to General Foods, manyother food processing companiesuse slipsheets and push/pull handlingattachments such as Campbell Soup,Kellogg, Carnation, Del Monte, Heinzand Ralston Purina. Beverage, paperproduct and building materialcompanies also use this method.

Electronic productsIn the electronic products arena.Apple Computer, Hewlett-Packard,and Micropolis Corporation havebeen very successful with palletlessdistribution systems, shippingcomputer products on slipsheets inocean containers and by air freight.In 1987, Apple Computer, withCascade Corporation’s assistance,became a pioneer in the implemen-tation of an international (US, Europeand Singapore) palletless handlingsystem. Apple’s idea was unique inthat it required the entire supplychain from end-users to OEMs toshippers to use the same handling/shipping method, namely slipsheets.The plan, which had major

implications for many otherelectronics companies, included an18-month program to change thesupplier network to unitized loadson slipsheets. During the first fullyear of operation, Apple saved overU.S. $2.5 million on a U.S.$200,000 investment in equipmentand start-up costs. Broken down, thisrepresented cost savings everywherein the distribution chain:

■ 20% reduction in freight costs.■ 75% reduction in unloading labor.■ 78% reduction in pallet costs.

“Another requirement forsuccessful pallet-less handlingis commitment”

A key to Apple’s successful palletlesshandling scheme was its partnershipwith Cascade Corporation, the push/pull attachments supplier. A com-puter-aided warehouse managementsystem (SPOC) was also designed toreap the benefits from using slipsheetsand Cascade push/pulls. Accordingto Apple, another requirement forsuccessful palletless handling iscommitment – from top management,sales and marketing, and manufac-turing. In addition, all the peopledirectly impacted by the change –vendors, carriers, and customers –must be educated about how thesystem works and what thebenefits are.

Hardware productsHome Depot converted to palletlesshandling to meet one overridinggoal: the reduction of financial andenvironmental costs. In mid-1994,the company set a very ambitiousgoal, based on its knowledge ofApple’s earlier successes – to convertitself and all its vendors (over 5,000suppliers) to a palletless handlingsystem by January 1, 1995 in a bid

to reduce shipping and handlingcosts. It also wanted to identify away to reduce the impact that use ofwood pallets was having on theenvironment, so slipsheets were itsnatural choice. In addition to thecost savings, one of the company’svendors reported a 30 percentdecrease in damage due to the useof slipsheets.

EUROPEAN SKIDBOARDS

In the UK, where slipsheets aremore commonly known as ‘skid-boards’ or ‘slip pallets’, at least 28large shippers use slipsheets whereeconomic justification is often relatedto shipments of exported goods incontainers. For this reason majorexporters of liquors – Dewar, Haig,Chivas, Strathleven Bond and JohnnyWalker – are all slipsheet users. Notall UK applications are related toexports, however. At English ChinaClays Sales Co., Ltd., Cornwall, fifty55lb. sacks of powered ball claysare unitized on 52" x 47" expend-able skidboard sheets. The loads arestacked five-high in the warehouse,and sideloaded for shipment ontolorries using Cascade push/pullattachments. The clay company’spromotional literature informscustomers that the skidboards aresupplied free, offering many advan-tages over pallets such as lower cost,easier disposal, greater stack stabilitywith a 20 percent saving in space,and the fact that they can be usedwith or without pallets on thereceiving end. Other slipsheet usersin England include the consumerelectronics companies Sharp, Sonyand Panasonic.

The use of slipsheets is alsoincreasing in France, Germany,Belgium, Holland, Italy, and Spain.One industry observer noted recently

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that; “The investment carried in pal-lets is usually greater than theinvestment carried in the lift-trucksthemselves”, and any way of reduc-ing this massive investment must begiven careful consideration. A newlaw in Germany affecting US busi-nesses’ use of pallets states thatcompanies which originate a pack-aging product which eventually endsup in the solid waste stream inGermany will be held responsiblefor disposing of that packaging. Thismeans that one-way wooden palletsare not acceptable.

Europeans seeking innovative alter-natives to pallets have found somecreative and unique ways to use slip-sheets. One example is the use ofcaptive sheets in place of captivepallets to facilitate loading. The VanDer Ploeg Zaden BFA Seed Companyof Barendrecht, Holland, is one ofseveral European companies usingthis approach. Seed bag unit loadsare stacked, three and four high, inthe warehouse. When they load intooutbound trucks, a special sheetretaining device on the lift-truckpush/pull attachment grips and holdsthe sheet as the load is pushed off.The sheet can be reused severaltimes whereas a pallet would beimpractical for this type of operationbecause of its height and sharp cor-ners. Corrugated boxes with slip

tabs are being used to import autoparts by Nippon Denco in Hollandfor distribution throughout Europe.

PALLETLESS HANDLINGIN JAPAN

The concept of palletless handlingwas introduced in Japan by Cascadein the mid-1960s. It experiencedlittle growth until 1978, whenchanges in Japan’s transportationcodes strictly forbade overloadinghighway vehicles. The reduced pay-loads caused by the weight andcube of pallets used for truck ship-ment, along with the very high costof wood pallets in Japan, accelerat-ed interest in the palletless method.companies that have recently con-verted to slipsheets for highwaytransport of goods include shippersof electrical appliances, electronics,milk, rice, confectionery products,liquors and canned goods. TheJapanese Physical DistributionRationalization Institute enthusiasti-cally promotes slipsheet utilizationvia the distribution of literature,training seminars, and study teamtours to observe application in theUS and Europe.

QUALITY

The slipsheet, made of corrugatedpaper, solid fiber or plastic, mustbe matched to the job for optimumperformance in a palletless han-dling system. A key part of the eval-uation includes an accurate costestimate of the slipsheet type. Itmay be possible, after a successfulconversion to slipsheets, to experi-ment with lower cost sheets, but tojustify the project based on a mar-ginal quality sheet can often be amistake. To determine what type ofsheet is the best value requires thesupport of a knowledgeable slip-

sheet supplier, who will assist inconsidering such things as:

■ Weight and dimensions of theunit load.

■ Size of gripper tabs and num-ber of score lines required.

■ How many times the unit loadwill be handled in the mostextreme situation.

■ What conditions, such ashumidity or contamination,might exist that could affectslipsheet strength.

■ If a surface treatment isrequired to prevent slippagebetween the load and slipsheet.

Fortunately, today a large knowl-edge base exists in the use of slip-sheets, as well as complete pallet-less handling systems, costs and attachments.

LIFT-TRUCK ATTACHMENTS

A successful palletless handling sys-tem is dependent on the functional-ity and quality of the slipsheet’spartner: the attachments used onthe lift truck.

Push/PullsCascade makes two types of push/pulls currently in use worldwide: theModel 35E/45E dedicated units, andthe Quick Fork Mount (QFM) push/pull units for dual usage lift-trucks.

The 35E push/pull is a rugged,lightweight unit designed forshort-wheel-base counterbalancedtrucks in the 3,000 to 4,500lbs.capacity range. Its high produc-tion slipsheet handling capabili-ties include platens that areadjusted just like conventionalforks, full bottom taper platens,4° tilting faceplate, high visibilitypantograph, and faceplate and

Figure 4: The slipsheet, what it is all about

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gripper mechanism designed tohandle all types of slipsheets. Theunit is specifically designed to pro-tect the products and slipsheetsfrom damage. Features include T-1steel platens, protected hydraulicsand unitized construction with castprimary and secondary arms.

The 45E push/pull has all the samefeatures as the 35E with the differ-ence being that it is designed for allgeneral slipsheet handling applica-tions for lift trucks in the 4000-5500lbs. capacity range includingthose requiring double-load stack-ing. The Quick Fork Mount (QFM)push/pull mounts directly onto the

forks and can be installed orremoved in approximately oneminute. This type of push/pull isdesigned for operations that fre-quently require both pallet andslipsheet handling. Both the stan-dard and QFM push/pulls use thesame pantograph mechanism andfaceplate.

Carton clampsThe other popular method of pal-letless handling is clamping unit-ized loads directly. Carton clampshave been adopted by many manu-facturers and distributors for han-dling goods such as: appliances,

packaged foods, paper products,wine, consumer electronics andplastic products. Carton clamps canbe used successfully with any prod-ucts that have sufficient strength orpackaging to withstand the clamp-ing force. Additional benefits ofclamps are that no slipsheet isrequired, and that it has the abilityto order-pick tiers off a unit load.Carton clamps work best with uni-form loads that don’t have voids,but have a carton height greaterthan seven inches and a shippingcontainer with enough strength toprotect the commodities. Clampingprovides the same efficiencies of

Figure 5: Another option, the carton clamping system

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better space utilization in ware-houses and in transport vehicles asthe push/pull and slipsheet systemprovides. Often, productive pallet-less handling will mean using bothpush/pulls and carton clamps.

Cascade Carton Clamps are made inthree weight categories: Models15D, 25D, 35D, and 50D, with vari-ous pad surfaces and size configura-tions available. The units are specifi-cally designed for durability andhigh visibility, and feature balancedforce distribution over the entirepad surfaces. Thin-profile outsidearms provide easier knifing between

loads during trailer or railcarbreakout. The 15D and 25D Clampsare designed for lift trucks in the2000-5000lbs. capacity range, andare used for handling relatively lightunit loads such as consumer paperproducts. The 35D Clamp is a gen-eral-purpose clamp suitable fornearly any single unit load, and isdesigned for lift trucks in the 3500-5500lbs. capacity range. The 50DCarton Clamp is used for heavy sin-gle unit loads such as wine, anddouble unit load handling. It isdesigned for lift trucks in the 6000-8000lbs. capacity range.

CONCLUSION

In the product handling and distri-bution future, there will beincreased demand to reduce costsand to be more environmentallyresponsible. Material handling unit-ized loads without pallets willreduce costs, save trees, andreduce the energy required totransport, manufacture and storepallets. The cost differentialbetween pallets and slipsheets willcontinue to increase. Also expectgovernments to continue legislatingsanitation and disposal regulationthat will make pallet use even moredifficult and costly.

Industrial VehicleTechnology ‘95

Contributed by Liz Nakazawaand Bill Peterson, TechnicalCommunications; and MikeTobin & Madalyn Piar-Katter,Cascade Corporation, USA

Figure 6: A sequence of loaded Cascade push/pulls

12

Unitizing & Slipsheeting

PUT IT ON A SLIPSHEET!

“There is an opportunity to savemoney in palletless handling.”Unitizing and slipsheeting are twoideas.

By David K. Spencer

To understand the present and futuretrends in unit load handling, a briefreview of it is in order. The greatestgrowth in unit load handlingoccur-red following World War II. Itwas determined then that a loadcould be handled more economicallyby unitizing it rather than handstacking and hand unstacking.

Several methods of handling unitizedloads were originally considered.Some of these included unitizing ona pallet or palletless with clamp orslipsheet. The unitized load on awooden pallet was adopted as themost popular system initially becausethe wood pallet was low in cost,availability of wood was adequate,and it was easy to teach an operatorto handle the product on the woodenpallet. The necessary equipment tohandle the product on the woodenpallet was also lower in cost. Apallet exchange system was estab-lished under the direction of theGMA (Grocery ManufacturersAssociation) to govern the exchange

of pallets between shipper andreceiver. It was called the GroceryPallet Council (GPC).

In theory, the exchange system willwork. In practice, it failed and inJanuary 1979, the GPC was disbanded.The reason – pallets returned wereinferior to those shipped. Palletshad increased in cost from $3.00 to$8.00. Pallets were not returned insome cases, the pallet now consumes50 percent of hardwood producedin the USA and 15 percent of totalwood production. Pallet maintenancewas costly, loss of cube and weightof the pallet and sanitation becamea problem due to rodent leavings inthe pallets which were stored out-side. Because of these reasons, pal-letless handling systems are beingreevaluated.

THE CLAMP

The clamp is one alternative that hasbeen adopted by manufacturers anddistributors for handling loadswhich lend themselves to clampoperations. Clamps work well withuniform loads that have no voids,have a carton height greater than 8inches and a shipping container

with sufficient strength to protect thecommodities. The clamp was prima-rily used in the warehouse for stor-age although it can be used to floorload product in railcars and trucktrailers. Most clamp loads are trans-ferred to pallets or slipsheets forshipment. It has steadily grown inpopularity. Today, 80-90 percent ofall paper rolls are handled by clamps,a high percentage of cartoned paperproducts, appliance, and some foodproducts are also clamp handled.

The slipsheet palletless unitized loadsystem was also evaluated by manycompanies and was adopted initiallyby companies primarily to ship andreceive their product at their ownmanufacturing and distribution cen-ters. The slipsheet eliminated thecost of the pallet exchange systems,weighed less, and utilized spacemore efficiently. Companies likeHunt Wesson adopted carton clampsto warehouse their products at theprocessing plants on the West Coastand transfer their loads by clamp toslipsheets for shipment to Midwestand East Coast markets. They werereceived at the company owned-and-operated distribution centers andtransferred back to pallets initially.About six years ago, they eliminatedtransferring the loads back to palletsfor storage and began warehousingdirectly on slipsheets. Other

1. Line up the platens squarely with theload.

2. Raise the platens about three inchesabove the floor

3. Tilt the mast forward until the tips ofthe platens touch the floor.

This article is adapted from apresentation made at a

meeting of thePackaging Institute.

■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

13


companies ship and warehouse theirproducts similarly, including suchcompanies as Libby’s, Cal-Pak,Carnation, Seagrams to name a few.The latest major company to makethe switch is General Foods. Othermajor processors are now evaluatingthis system or have made the com-mitment to make the conversion.Examples of these companies includestandard Brands and Lever Brothers.Slipsheets have been received atmajor grocery chain warehouses onrailcar siding for a number of years.Few truck shipments have been madebecause it is the common practicefor the truck driver to unload hisown vehicle and the cost forunloading the truck trailer isincluded in negotiated tariff rate.

Times are changing. One majorreceiver, Jewel in Chicago, isrequesting suppliers to ship to themon slipsheets because they want toeliminate the problems associatedwith the exchange pallet on theirloading docks. Truck shipments arecommon between producer andtheir distribution center where thedistribution center is unloading thetruck trailer rather than the truckdriver. Most major grocery receivershave not actively requested unitizedslipsheet loads across their docksand some have discouraged theseshipments because they did not feelthey will benefit from this system.Some of their reasons include:

■ added cost of equipment tohandle slipsheet

■ driver training required■ additional time to transfer

loads back to pallets■ poor condition of the slipsheet

loads sometimes requires morethan one person to unloadthe load

These problems can be overcome atthe shipper, receiver and equipmentsuppliers work together. Examplesof the benefits from this cooperationinclude:

Lower cost of equipment■ Crown outrigger truck with

sideshift push/pull having acapacity of 3,000 pounds liftsup to 60 inches. Cost $15,000.

4. Drive the truck forward until the platentips are under the slipsheet lip.

5. Extend the pusher plate so that theslipsheet lip fits into the gripperchannel opening

6. Retract the pusher plate. The gripperbar will automatically clamp the slip-sheet lip.

7. Move forward slowly as the load isbeing pulled onto the platens.

8. As the weight of the load is transferredto the platens, they will deflect down-ward slightly. Raise the carriage aboutone inch to prevent the platen fromdigging into the floor. Slowly tilt themast to a vertical position as youscoop up the load.

9. Tilt the mast back, and raise the loadthree-to-four inches above the floor.Your are now ready to transport theload.

14


■ Yale ESC modified electriccounterbalance truck withsideshift push/pull, lifts 2,500pounds up to 60 inches and2,100 pounds to 130 inchesand can carry pallets.Cost: $21,000.

■ Clark Walkie with push/pullhaving a capacity of 3,000pounds. Cost: $15,000.

■ New Walkie Push/Pullscheduled for release from Cascade September 1979. Cost: $11,000 approximately with OEM Walkie. Capacity 3,500 pounds.

■ Light-weight push/pullscheduled for release from Cascade August 1979 for counterbalanced truck and outriggers, 3,000 pound capacity, 500 pounds lighter than the present unit and 1 1/2 inches less lost load to increase truck capacity.

Slipsheet StandardsCommittee

■ ANSI (American NationalStandards Institute) form ofadhoc committee members ofcompanies and personnelinterested in establishing slipsheet standards.

■ API (American Paper Institute)composed of slipsheet manu-facturers representatives toestablish volunteer slipsheetstandards and a movie on theproper method of handlingslipsheet standards.

Regional seminars are being pre-sented throughout the nation toeducate users and to assist them.McDonald’s has recently stagedcoast-to-coast visits with these semi-nars. In addition the United FreshFruit and Vegetable Association, New

York Chamber of Commerce as wellas a major slipsheet manufacturerhave conducted seminars. Cascadehas participated in these seminarsto train the key representatives ofthe users of slipsheets, the local lifttruck dealer salesmen and slipsheetsalesmen in the proper techniquesof material handling with slipsheets.Slipsheets, properly used, will bene-fit your system and save money inmaterials handling. Improperlyused, they create frustration and canreduce economical justification.

Cascade has assembled a manualthat reviews the benefits of slip-sheet handling, proper driver tech-niques, how to assemble a load,speeches and periodicals on thesubject, slipsheet suppliers, typesof slipsheets, outline for justifyingeconomically, the slipsheet han-dling system and on-the-jobreports. One of these can be fur-nished to you.

In summary, the slipsheet systemcan be used by itself or in conjunc-tion with the wooden pallet. Youmust make the decision. There isan opportunity to save money inpalletless handling of your prod-ucts by using slipsheets. The deci-sion is yours.

Reprinted from the October1979 issue of Paper Board

Packaging with permission ofJoel J. Shulman, Editor,

Magazines For Industry, Inc.

15

Global Progress

PUSH-PULL’S GLOBALPROGRESS

Slipsheets are spreading world wideas innovative applications appear.

During a recent visit to the UnitedStates, members of a Japanesephysical distribution study teamwere asked what they called slip-sheets in Japan. Without hesitationand with hardly a trace of accent,they chorused, “Slipsheets.” Thegeneric terminology as well as thetechnology appears to have beensuccessfully exported to the Far East.

Invented in the United States 33years ago, (see H&SM, Oct. ‘78, pg.42), the push/pull slipsheet methodof unitized handling and shipping isbeginning to spread throughout theworld. Today slipsheets are used inEurope, South America, and the FarEast, to handle goods ranging fromchemicals and electrical appliancesto food cases, seed bags, cementand beer kegs.

The reason for the interest in themethod abroad are the same in theUnited States. The sheets offer a rel-atively inexpensive unit-load basethat uses little space, weighs only acouple of pounds, and requires norepairs – all increasingly importanteconomic factors in today’s envi-ronment of continuously risinglabor, material, and energy costs.

Japanese companies that haverecently converted to slipsheets forhighway transport of goods includeshippers of milk, electrical appli-ances, confectionary products,liquors, and canned goods. Thesheets are used mostly for trans-port. Unit-loads are warehoused onpallets then transferred to slip-sheets for over-the-road haul.

The concept was introduced inJapan ten years ago by the CascadeCorp-oration, a U.S. manufacturerof lift truck attachments. It experi-enced little growth until 1978, ayear which brought changes toJapan’s transportation codes thatstrictly prohibit overloading high-way vehicles. The reduced payloadscaused by the weight and cube ofpallets used for truck shipments,along with the high cost of woodenpallets in Japan, accelerated inter-est in the palletless method.

There are seven key suppliers ofslipsheets in Japan today. Rento,Mead, and Bunyusha supply solidfibre sheets; Fukoka Seishi, corru-gated sheets; and Nippon PetroChemical, Mitsui Toatsu andIdemitsu Petro, plastic slipsheets.

In addition to Cascade, severalJapanese companies, Toyota,Komatsu, Mitsubishi and NipponYusuki, have joined the ranks ofpush/pull attachment manufactur-ers. Sales of slipsheet attachmentsreportedly have doubled within a year.

The Japanese Physical DistributionRationalization Institute, chaired bySojiro Kamiyama, has actively pro-moted slipsheet use through distri-bution of literature, training semi-nars, and study team tours toobserve applications in the United States.

BRITISH APPLICATIONS

In England, slipsheets are morecommonly known as “skidboards”and “slip pallets.” At least 28 largeshippers use sheets. The relativelyslow growth compared to theUnited States is attributed to thescarcity of high quality, low costpaperboard sheets, the high cost of

plastic sheets, and the difficulties ofadapting sheets to warehouse oper-ations, many of which utilize nar-row aisle reach trucks.

Where successful applications arefound, economic justification isoften related to shipments of export-ed goods in containers. For that rea-son, major exporters of liquors –Dewar, Haig, Chivas and StrathlevenBond – are all slipsheet users.

One of the large shippers usingsheets is Cadbury at Marlbrook(Herefordshire). To assure goodspace utilization for the company’schocolate products in ISO contain-ers, pallets had been avoided, andthe cases handpiled into containers.

Loading a typical container tookabout six manhours, and that wascostly since half the company’sannual chocolate production isexported in containers.

The use of sheets permit fast unit-ized handling on both shipping andreceiving ends.

Not all English applications arerelated to exports, however. AtEnglish China Clays Sales Co., Ltd.,Cornwall, fifty, 55-pound sacks ofpowdered ball clays are unitized on52" by 47" expendable skidboardsheets. The loads are stacked five-high in the warehouse, and side-loaded for shipment onto lorries byCascade push/pull attachments. Thefirm’s promotional literatureinforms customers that skidboardsare supplied free, offer manyadvantages over pallets such aslower cost, easier disposal, greaterstack stability with a 20 percentsaving in space, and finally, can beused with or without pallets on thereceiving end.

16

Global Progress

EUROPEAN PRACTICE

Slipsheet use is also increasing inFrance, Germany, Italy, and Spain.There are six suppliers of paper-board sheets; five suppliers of plastic sheets.

Push/pull attachments are availablein most European countriesthrough Cascade and three othermanufacturers; Meyer and Kaup inGermany, Bolzoni in Italy.

Applications in Europe have beenmostly for bagged or sacked goodslike cement, seeds, and feeds. Theseloads are often handled by conven-tional forks in conjunction with“take-it-or-leave-it” type pallets andthe chisel-under handling method.This handling avoids immediatepurchase of push/pull attachments.

Use of sheets as an alternative topallets is under study at manyEuropean companies for economicreasons, since, as one observernoted recently, “the investmentcarried in pallets is usually greaterthan the investment carried in thelift trucks themselves, and any wayof reducing this massive invest-

ment in pallets must be givencareful consideration.”

Slipsheets have sometimes beencriticized for not being as univer-sally applicable as pallets. However,industry innovators have foundsome unique ways to use sheets.

One such application is the use ofcaptive sheets in place of captivepallets to facilitate loading. The VanDer Ploeg Zaden, BFA SeedCompany of Barendrecht, Holland,is one of several European compa-nies using this approach.

Seed bag unit-loads are stacked onsheets, three and four high in thewarehouse. When loaded into trucks,a special sheet retainer device on thepush/pull attachment grips and holdsthe sheet as the load is pushed off.The sheet is used several times.

Due to height and sharp corners,pallets are impractical for this kindof operation.

At Bahlsen, a large biscuit manu-facturer at Hanover, Germany,paper sheets have been integratedinto the order assembly process.Products are unitized with a sheet

under each tier in the unit-load.The sheeted loads are then stagedalong a warehouse aisle and astacker vehicle with a special grip-per-puller device on board, movesalong the aisle and grips and pullsone or more tiers of each productonto a low wheeled “buggy”.

The sheets permit transfer of oneor more tiers at a time. The methodis more functional than suctionhead units which can transfer onlysingle tiers at a time.

Assembled unit-loads of mixedproducts are then delivered to thestaging area and pushed onto theoutbound route vehicles.

In New York, the popular air cargopallet box of Containair SystemsCorp., has recently become availablewith heavy duty slipsheets substitut-ed for the pallet bases. The box canbe handled easily by conventionalforks chiseling under each load.

According to Julius B. Kupersmit,president of Containair, the slipsheetversion costs less, reduces tare weight28 pounds for each box, and increas-es the useable volume 12 percent.

A lift-truck with a push/pull attachment loads an ISO containerwith electrical appliances. Slipsheet shipping is increasing inJapan due to a new law banning highway vehicle overloading.

Three separate U.S. companies manufactured the lift truck, slip-sheet attachment, and the slipsheet in use at Van Der Ploeg ZadenBFA Seed Company in Barrendrecht, Holland.

17

Global Progress

Another kind of large corrugatedcontainer with a slipsheet base hasbeen developed and tested by UnionCamp Corp. for produce shipments.

Even watermelons have beenshipped in the large bins.

Flexibility of base dimensions is adistinct advantage for slipsheetsover pallets for many users. Oneshipper observed that “for years wewere tied to the 48" x 40" palletbase since it was impractical tomaintain separate inventories ofseveral different size pallets. It is arelatively simple matter to changebase sizes on slipsheets.”

Even rapid turnaround methodshave been successfully adapted toslipsheet unloading. AutomaticTruckloading Systems (ATS) ofEaston, PA, exhibited an innovativetrailer cable floor system at the 1979National Material Handling Showthat can unload an entire trailer ofslipsheet unit-loads in minutes. (SeeH&SM, June ‘79, pg. 60)

Such a system is in use at theHershey Chocolate plant at Hershey,PA., to shuttle loads both within theplant complex and to a warehousein Mechanicsburg, PA.

UNTAPPED POTENTIAL

Potential exists for annual savingsexceeding 150 million dollars forcommon carrier transport of foodproducts on slipsheets, accordingto John C. Bouma, of the MarketResearch Division of the USDA.Speaking at a meeting of the FoodDistribution Research Society atPortland, Oregon recently, Mr.Bouma based his reasoning onUSDA field studies of comparativecosts of shipping methods, and asurvey of 129 food warehouseoperators that revealed unitized

Paper sheets have been integrated intothe order assembly process at a compa-ny in Hanover, Germany. Products areunitized with a sheet under each tier inthe unit load. Sheeted loads are stagedalong a warehouse aisle and a stackervehicle with a special gripper-pullerdevice on board moves along the aisleand grips and pulls one or more tiers ofeach product onto a low wheeled buggy.As assembled unit-loads of mixed prod-ucts are then delivered to the stagingarea and pushed onto the out-boundroute vehicles. (left)

ROLLAX TIERING MACHINE

▲

▼

▼

▼

▼

▼

1.

2.

3.

4.

Transfer Device MountedOn Stack Crane

Buggy To ReceiveLoad Layers

Transfer Table

Slipsheet Lip

Loads In Rollax Gravity Feed Racks

18

Global Progress

unloading of common carriertrucks is almost non existent.

Mr. Bouma noted that althoughlow-cost material handling equip-ment exists for unloading palletloads across truck docks, carrierslose revenue due to pallet weightand cube, which offsets a large partof the potential savings of palletized handling.

Slipsheets do not result in such lossof revenue, he noted, but are not inwide use either because suitableequipment to handle slipsheet loadsis seldom found on truck docks.

Furthermore, little incentive existsfor the receiver to provide the dock equipment as the freight costs for

most grocery loads are pre-paid and the carrier does theun-loading as part of the rate.

Mr. Bouma suggests that thefirst step to implement slip-sheet unitization in commoncarrier trucks be transfer ofthe unloading allowance now

included in the tariffs from carrierto receiver.

PALLET VS. SLIPSHEET

Despite the successful integration ofslipsheets and pallets in many appli-cations, the methods continue to bedebated by those intent on provingthere must be “one best way.”

This was evident in the reactionsfollowing issuance of the USDAMarketing Research Report No.1075, titled “Systems for HandlingGrocery Products from Supplierto Distribution Warehouse.”

The report, prepared by the USDAScience and EducationAdministration’s Federal Research

Staff, contained cost data on a varietyof grocery product shipments basedon the observations of fieldresearchers during 1974 and 1975.Due to delays in data reduction andpublication, the report was notissued until June, 1978. Slipsheet usehad grown substantially during theinterim.

At the time of the USDA study, itemsobserved on slipsheets were pre-dominantly high bulk low-densitytypes like cases of cereals or paperproducts that averaged only 39cases per unit-load. Pallets werecarrying mostly low bulk, high den-sity items like cases of cannedgoods, which averaged 68 casesper unit-load.

These fundamental differences in thekinds and quantities of items shippedby each method, coupled with datasummarization in terms of cost-per-1000 cases and 1000 pounds, result-ed in incorrect interpretations.

For example, in the data summaryconcerned with loading rail cars,labor, equipment, material, anddunnage costs, averaged $51.26per car for the palletized loads and

A slipsheeted, stretch-wrapped load of citric acid is placed on apallet with standard forks in an experiment at Pfizer’s Southport,N.C. plant.

A large corrugated container with a slipsheet base made by UnionCamp Corp. has been used to ship produce, including watermelons.

Cables in decking of trailer move totransfer slipsheet loads from trailerto receiving dock at the HersheyChocolate Plant in Hershey, PA.

19

Global Progress

$36.78 per car for the slipsheetloads. The smaller cases on palletstotaled 3,012 cases per car, versus1,863 cases per car for the bulkiercases on slipsheets.

Cost-per-1000 cases therefore cal-culates to $17.01 for pallet ship-ments and $19.74 for slipsheetshipments. This led several tradepublications to announce the USDAreport with superficial headlines tothe effect that “Governmentresearch proves superiority of pal-lets over slipsheets.”

On the other hand, several readersimmediately noted that if adjust-ment to the weighting factors weremade to show the same number ofcases per unit-load on slipsheets ason pallets, the cost-per-1000 casesfor slipsheets would drop to$12.21. Conversely, if the palletshad been carrying the bulkiercases, their cost-per-1000 cases

would have been $27.51.

Actually, little can be con-cluded from such dataexcept that the number ofcases on pallets and slip-sheets was not comparable,and the density of goodshandled will affect unit-loadhandling costs, whether pal-lets or sheets are used.

The American Paper Institute(API), a trade association repre-senting most U.S. Sup-pliers offiberboard slipsheets, became con-cerned with the adverse publicityabout the USDA data (on costs-per-1000 cases) that failed to explainthe differences in unit-load weightsor case counts.

Subsequent discussion between theInstitute and USDA officials resultedin a USDA letter to the API confirm-ing the significant differences in the

unit-load weights and case countsused in the report. The API subse-quently decided to pursue the mat-ter directly with shippers andpotential users of slipsheets.

ANSI RECOGNITION

Within the past year, slipsheets havebeen recognized for the first timeby the American National StandardsInstitute (ANSI). The title of theANSI standards committee MH-1that previously considered strictlypallets as a means of unitization,

Containair’s air cargo pallet box hasrecently become available with a heavy-duty slipsheet base.

A low-cost lift truck is adapted topull unit-loads on slipsheetsfrom trailers (below) ontocaptive pallets for warehousestorage (1.) at Nabisco.

20

Global Progress

has been changed to “MH-1,Standardization of Pallets, slip-sheets, and Other Bases for Unit-Loads.” An ANSI MH-1 subcommit-tee is drafting a proposed slipsheetstandard that will provide standarddefinition and basic specificationsfor industry wide use.

In anticipation of continued expan-sion of the slipsheet method abroadand for international containerizedshipments, attendees of the TC-51committee of the InternationalStandards Organization (ISO) inLondon, England, in January 1979,were posted on progress in thedevelopment of an ANSI slipsheetstandard and the possibility of itbecoming an ISO standard.

Although the rationalization of slip-sheets as a unitized method is wellunderway, the issue of pallets ver-sus sheets continues because thesheets have emerged only recentlyas a viable alternative and are stillin the adaptive stage.

Many shippers already know thatsheets can complement pallets in aunitized system, with pallets used instorage and slipsheets in transit.This is particularly the case whereunit-loads are stored in rackswhich require a rigid base.

Slipsheets either ride with the loadson pallets through the storage racksystem, or the unit-loads may betransferred from the pallets ontosheets at the shipping docks.

The needs for new and improvedmaterial handling equipment toprovide cost effective interface ofthe two methods at shipping dockscontinues. In the absence of com-mercially manufactured equipmentto do the job, one shipper, Nabisco,developed its own equipment totransfer inbound slipsheet unit-

loads received in trailers, onto pal-lets for storage.Generally needed is a low costdock truck to extract slipsheetloads from trailers as efficiently aslow cost pallet jacks and trucksremove pallets. Several companiesmarket low lift pallet trucks withslipsheet attachments, but cost isabout $15,000 each. At least twomanufacturers are working on theequivalent of a pallet jack for slip-sheets that will sell for about$5,000 each, but are not yet ready.

So, as new equipment continues toappear, and innovative ways toemploy slipsheets are found, thereappears to be little doubt that theslipsheet method has gained astrong foothold. The method willcontinue to grow and contribute toeconomical handling and shippinggoods and materials throughoutthe world.

Reprinted from the December1979 issue of Handling &Shipping ManagementMagazine H.G. Becker, Jr., Editor.

21

The Pallet's Successor?

SLIPSHEETS:THE PALLET’SSUCCESSOR?Kansas City – Will the slipsheeteventually replace the wooden pal-let in the fresh produce industry? Itmay be too early for an accurateprediction, but with uncertaintiesover future wood availability, esca-lating lumber costs and the prob-lems of what to do with large, cum-bersome wooden pallets once theyreach their receiver, it is little won-der other alternatives to this dilem-ma are being considered.

When it comes to produce han-dling, slipsheets have been creatinginterest within the fresh fruit andvegetable industry. Slipsheets arenot new. While fiberboard slip-sheets have been in productionabout 25 years, plastic slipsheetshave been around less than adecade. But slipsheets in generalare relatively new to the produceindustry, although they are com-monplace in grocery shipments.

Just about anywhere one lookstoday, slipsheets, if not being used,are at least being considered. Whilethe problem in produce shipmentshas often centered on a standard-ized wooden pallet, some produceshippers are wondering whetherthey should use wooden pallets atall.

For example, there are the one-way35"x 42" softwood pallets used bythe grape and tree fruit shippers inCalifornia. Overall in the produceindustry, there is greater use of the40"x 48" hardwood pallets. Theseparticular shippers may like thewooden pallets, but this is not nec-essarily the case with receivers inthe Midwest and East who have to

find ways for disposal. Disposal, infact, may be the foremost problemwith pallets. There have even beenpallet pools (exchange programs)established, but with limited success.

Just recently, a member of GroceryPallet Council (GPC) spoke at ameeting and said unless the palletpool is turned around in the nexttwo years, the GPC will be out ofbusiness. Not only have problemsexisted at the mill level where somepoor quality pallets are being pro-duced, but the return program forpallets has been a miserable failurein many instances.

Shippers commonly talk aboutshipping their fresh produce east-ward on top-notch wooden pallets,only to have pallets returned dam-aged and in such poor conditionthey have to be thrown away. Thisis where slipsheets come in – theyare easy to dispose of.

While shippers are showing interestin slipsheets, they also must look atthe advantages and disadvantagesof the plastic slipsheet – versuspaperboard, fiberboard and corru-gated slipsheets. But first, the prosand cons of slipsheets in generalversus the wooden pallet are more pronounced.

Speaking at a transportation meetinglast fall, Gordon Bard, head of theProductivity Committee of theAmerican Frozen Food Institute’sPhysical Distribution Council, point-ed out the advantages of paperboardslipsheets over wooden pallets.

COST COMPARISONS

While hardwood pallets cost any-where from $4 to $13 per pallet in1976, paper board slipsheets aver-aged only 37 cents to $2.50 apiece.But this is just the beginning.

Other advantages include: The ship-per normally gets back a pallet inworse shape than the one heshipped; wooden pallets requirerepair, while paperboard slipsheetsare easily disposable; there is apossibility of hardwood shortages,but not with slipsheet materials;fifty paperboard slipsheets can beplaced in the same area as one pal-let; 10 percent more space isobtained in rail cars with slip-sheets; slipsheets are safer withoutsplinters and nails, and no return isrequired with fiberboard slipsheets.

While the advantages of plasticsheets are similar to the advantagesof paperboard sheets over woodenpallets, there are a couple of differ-ences. In produce shipmentswhere top icing in general isinvolved, paperboard slipsheetshave been known to tear, a prob-lem which does not affect plasticslipsheets. And at least one manu-facturer of plastic slipsheets offer a40 percent return on every dollarto its customers who return theirpurchased slipsheets.

Plastic slipsheets in 1976 normallyranged from $1 to $3, dependingon size, thickness and entry.Depending on size, a softwood dis-posable pallet cost $2.50 to $4.

PALLET PROBLEMS

One example of the produce indus-try’s interest in slipsheets is inCalifornia. Roger Rij, AgriculturalResearch Service, U.S. Departmentof Agriculture, Fresno, has beenresearching slipsheets for theCalifornia Tree Fruit Agreement, astudy stemming from grower inter-est. Shippers of plums, nectarines,peaches and other tree fruit herehave been unitizing their shipmentson 35"x 42" one-way softwood dis-

22


posable pallets. But whether theseshipments are directed to terminalmarkets, or chain store operations,receivers are still faced with dispos-al problems. Rij said these palletshave to be broken down into small-er pieces for disposal and eventhen they “can’t even get thegarbage disposal companies to getrid of them.” He noted Californiashippers would use the hardwoodtwo-way pallets, but they don’t likethe idea of shipping out good pal-lets and “getting junky ones back.”

One move that has helped in thisarea is the free pallet program,which the Santa Fe Railroad initiat-ed in the fall of 1976. For every fivecar-lots of produce shipped east,one carlot of pallets will bereturned. Shippers are not chargedfor the transportation of the palletsin either direction.

Although Rij is still in the middle ofthe study, he seems to be impressedwith slipsheets. However, at thesame time, he stresses the USDA isconducting an impartial study. “TheUSDA does not care which way it

goes (slipsheets or wooden pal-lets); we just want the bestmethod,” Rij said.

One advantage of slipsheets citedby the researcher is that by usingthe product on a truckload of treefruit, a shipper can load up to 600more pounds of fruit than if hewere using wooden pallets. Butbefore he gives a final stamp ofapproval on slipsheets, Rij has a lotmore testing to conduct.

He said there “are things we do notknow yet. How does it (slipsheets)affect air distribution and cooling?We want to get down to the realnitty gritty,” Rij said. “We want tocompare the ease of handling,quality and cost in our research.”

The project included two shipperslast summer who cooperated in thetests and Rij said about four moreshippers have shown an interest inparticipating in the study next sum-mer. One of the main problems inconducting the experiment has beenfinding receivers with the properequipment to handle the slipsheets.

Phil Hale of the USDA’s AgriculturalResearch Service in Orlando, Fla.,said corrugated slipsheets have beenin commercial use by citrus packinghouses in the “Sunshine State” forfour or five years now. These slip-sheets are even being used success-fully in many export shipments.

But strategic produce growing statessuch as California and Florida arenot the only areas where slipsheetshave made inroads. Shippers ofpotatoes in Oregon, Idaho,Washington and Wisconsin are turn-ing more to the method.

SPUDS ON SLIPSHEETS

In December 1975, Jay Arend ofCentral Sands Produce, Inc.,Bancroft, Wis., started using 350-pound corrugated slipsheets. Arendbegan using the produce after hehad observed their use in otherareas. The potato packer-shippersaid the “cost of products (pallets)was getting outrageous.” Arend stilluses wooden pallets, but only on anin-house basis. “In our case andwith any shipper, you have a grave-yard of broken pallets,” Arend Says.“My feeling is this (slipsheets) is theway for the produce industry to go.”

Arend said wooden pallets werealright to use on short hauls if anexchange program is available, butthe extra weight of the pallets on theload, plus extra use of fuel are stillnegative factors to be considered.

The shipper said he feels some ofhis peers haven’t realized as yettheir advantages in using slipsheets,but he noted that at least three or

The Extender of this push/pull attach-ment is shown extended to the end ofthe platens. The gripper jaw, at the endof the attachment, is open and ready toclamp onto a slipsheet. (Photo courtesyof Cascade Corp.)

23


four other shippers in the area havetaken this direction.

Arend saves from $120 to $140 asemi-trailer load with slipsheets. Hecan load 4,000 unitized 10-poundbags of potatoes on 20 slipsheets. Ifa customer had to have these samepotatoes in 8,000 master contain-ers, costing 16 cents apiece, itwould cost $128 more. Arend alsomaintains receivers like the idea ofquick unloads. Instead of manualunloads taking two hours, unitizedunloads of potatoes on slipsheetsonly take 15 minutes. The shippersaid his palletized loads of potatoesnormally are shipped in 110-, 115-,and 120-pound packs.

BQP Industries, Inc., Denver, Colo.,has been manufacturing plasticslipsheets for eight years and aspokes-man said the company isthe oldest and largest manufacturerof this product. He noted the foodand beverage industries are thelargest users of plastic slipsheetsand one major beer produceralone has two and one-half millionsheets in its system.

While the use of slipsheets in gen-eral within the produce industryhas a lot of growth potential, thegrocery industry is much morefamiliar with this alternative towooden pallets. One of the mainproblems, however, is the specialequipment required to handle slip-sheets. Fork lifts require a“push/pull” attachment to movethese slipsheet-based loads. Cost ofthese special devices in 1976, notincluding fork lift (lift truck),ranged from $5,700 to $8,500,according to officials at ClarkEquipment Company, Battle Creek,Mich., who build lift trucks as wellas the slipsheet attachments.

However, there is one alternative tothe costly lift trucks. Clark Equip-ment has recently placed on themarket a “Walk/Ride Pul-Pac,”possible better known as a“walkie.” While a lift truck in 1976with the special slipsheet attach-ment cost $22,000 to $24,000, awalkie only cost about $13,000,including the push/pull attachment.The operator can ride this walkie,or operate it as a walkie unit.

Still, the old adage of “you pay forwhat you get” applies here. Thewalkie cannot stack loads, whichwould limit its usefulness in a ware-house. However, the walkie can beuseful moving palletized loads in orout of trailers and rail cars.

This particular walkie has a 3,000-pound rated capacity, operatesfrom a 24-volt battery and has athree-speed control, traveling up tosix miles per hour, while unloaded.

But there are other problems inusing slipsheets besides just thecost of special equipment.Apparently most receivers, at leastin the produce sections of ware-houses, do not have this equip-ment. Proponents of slipsheets saythe cost savings of the producealone as compared to the woodenpallet, will allow receivers to buyspecial equipment. However, thisclaim has not been readily accept-ed. Another problem involves thelabor unions.

In some areas of the nation, laborunions are much stronger than inother areas. While some producewarehouses are able to borrow lifttrucks with push/pull attachments,others, where there is union resist-ance, are not allowed to cross overinto another department to borrowthis equipment.

At BQP, a recycling program isavailable on plastic slipsheets. Thecompany pays 40 percent of theoriginal cost of the slipsheet whenreturned by a customer. Uponreturn, the product is run througha grinding machine, andreprocessed with a certain amountof virgin resin added.

Reprinted from the Sept. 301978 issue of The Packer withpermission of W.E. Coon VicePresident and Publisher.

A Special Section ofTransportation & Distribution,Edited by Thomas J. Andel,associate editor.

24

Packagers Ready?

ARE PACKAGERS READYFOR SLIPSHEETS?If current efforts to replace woodpallets with slipsheets prove suc-cessful, industrial packagers mayhave to reconsider their standardson load limits and operating costs.

By Alan Serchuk,managing editor

Industrial packaging may be on theverge of a new era—one in which thetried and true pallet gives way to a30-year old newcomer: the slipsheet,or, as some call it, the pull pack.

For years, the pallet formed thebase of unit-load shipments. Somego as far as to credit the pallet withthe current state of efficiency of thenation’s physical distribution sys-tem. But, for all of its virtues—andthere are many—and its almostubiquitous use, the pallet may final-ly be falling victim to a combinationof circumstances and ailmentsbrought about by those dependingon it most—the shippers them-selves. In its place, more and morehigh volume shippers, such as JewelFoods and General Foods, areadopting specially constructed andtreated sheets of corrugated andsolid fiber board and plastic to formthe base for their unitized loads.

What happened to the pallet? First,there’s the constantly rising cost.Sixteen years ago a 48" x 40" four-way hardwood pallet cost perhaps$3. Today it runs near $8. Then,there are the periodic materialsshortages due to the tremendousdemand for lumber by this industry.By one estimate, .6% of all lumberproduced in the US goes into palletmanufacture. Looking at hardwoodsalone, 50% to 55% goes into pal-lets, and by 1982, the estimate isfor between 75% and 90%.

Another area of concern: the risingcost of moving freight. With palletsweighing up to 75 lbs. each, thecost of shipping them can be signif-icant. For example, on a truckloadof 40 palletized loads, payload isreduced by 3,000 lbs; for a railcarshipment of 56 palletized loads thepayload loss comes to 5,000 lbs. Inaddition, there’s a cube loss of10% to 12%.

But, these problems aren’t new.Pallet users have had to deal withrising costs, sanitation, materialsshortages and a host of otherheadaches over the years. They’vedeveloped lightweight wood palletsas well as plastic and corrugatedversions. Suppliers even designedlegs that can be strapped to a loadin place of a pallet.

In addition, packagers, with thehelp of freight carriers, organizedpallet pools that provided a way ofreturning pallets to a shipper on aone-for-one basis. One of thewidest and most active of these wasorganized by the GroceryManufacturers Association (GMA),which also set standards for palletquality. Unfortunately, the pools didnot function as originally planned,and it was their failure that mostobservers blame for the currentshift to slipsheets.

For their part, shipsheets have notbeen met with total enthusiasm bypackagers. The early history of theseload unitizers included considerablefailure. The sheets just didn’t holdup to the demands of carrying per-haps a ton of merchandise.

Even now, slipsheets must be care-fully selected for the application.Being paper products, corrugatedstyles, for instance, don’t stand upwell to cooler temperatures com-mon to produce storage and ship-ment—the flaps tear off easilywhen they get wet. In fact, theUnited Fresh Fruit and VegetableGrowers Association advises ship-pers to use 100% virgin kraft fibreboard sheet. Such sheets, especiallywhen coated with a polyethylene orother moisture barrier, have been

25

tested for extended periods in tem-peratures as low as –20F.Completely submerged in water for24 hours they pick up only 4%moisture and that has little effecton flap strength. Where shippersinsist on corrugated, many pro-duce organizations suggest usingdouble slipsheets.

Slipsheet suppliers unanimouslyacknowledge early problems withmoisture and lip failure, but notequickly that technology has improvedin recent years to overcome most ofthem. Papermaking methods haveimproved, lips can be reinforced foradded strength, and surfaces can becoated to resist shipping and storageenvironments. Further, plastic sheetsare also available, which suppliersclaim can carry any load that a palletcan carry.

Industry performance standards donot yet exist. However, theAmerican Paper Institute and theAmerican National StandardsInstitute are both working on themand expect to have proposals readysoon. Until then, prospective userswill have to continue working withsuppliers to develop their own per-formance requirements.

Suppliers explain that so many vari-ables must be considered indescribing slipsheet perform-ance—materials and manufacture,types of load, environment, amountof handling, and equipment designare the major factors listed—thatthe only realistic way to design aslipsheet system is the empirical“cut-and-try” technique.

Still, most suppliers have enoughdata on their products to provide astarting point. For example, onelists tensile strengths for fourweights of solid fibre board as:

Packagers Ready?

Matters are somewhat differentwhen considering plastic slip-sheets. These 30- to 70-mil thicksheets presumably resist dents andpuncture that could destroy corru-gated or solid fibre units.

The biggest drawback to plastic isprice, which is about $2. Thatcompares with 50¢ for corrugatedand 70¢ for solid fibre. However,plastic sheets are reusable andrecyclable. One major cosmeticsuser can get 15 to 25 trips for asheet: three trips is consideredbreak-even. (Most plastic slip-sheets are used in tightly controlleddistribution systems so that theshipper maintains control overthem.) And, to increase the sheets’competitive standing, at least onesupplier allows a 25¢/lb rebate onplastic slipsheets turned in forrecycling. So far, though, plasticrepresents a fairly small part of thetotal slipsheet market.

EQUIPMENT:A MAJOR OBSTACLE

The relative merits of one type ofslipsheet over another may bedebatable-able. But, there’s littlequestion that the high cost of equip-ment is probably the largest obsta-cle to wider implementation of slip-sheet systems of any type. Considerthat all stations in a physical distri-bution system now own pallet-han-dling equipment. To adopt slip-sheets requires an investment of$5,000 or more for a simple pieceof gear.

The basic device is a push/pull unitthat grips the lip of the slipsheetand pulls the load onto a platen or

a set of wide forks. The full rangeof pallet-handling equipment canbe had in slipsheet versions, withfully equipped lift trucks selling for$30,000. A stand-up truck with a2,500-lb capacity costs about$21,000; and 3,000-lb rated outrig-gers and walkies go for $15,000.For stations already equipped forpallet handling, push/pull attach-ments are available at considerablylower cost. For example, estimatesfor converting a fork lift truck runfrom $5,000 to $8,000. Just con-verting the normal forks to the 15",wide highly polished and casehardened chisel-tipped slipsheetforks runs near $600.

A word of caution, though, whenconverting this equipment. Thepush/pull attachment sits astridethe lift forks, effectively reducingtheir length. But more importantly,lift trucks must be derated to com-pensate for the attachment’sweight—a normally rated 4,000 lbtruck might be derated to 2,900 lb,3,780 lb for a 5,000 lb rated unit.(Equipment manufacturers havefull details.) As a practical matter,derating could prevent a piece ofequipment’s being used to movedouble tiered loads.

Yet another cost comes with this typeof equipment. All sources emphasizethe need for special operator train-ing to make slipsheet systems work.Special techniques have been devel-oped for pulling slipsheeted loadsonto lift forks, chiseling under loads,picking off and depositing upper-tierloads, and maneuvering in railcarsand truck trailers.

MAKE YOUR OWN PLANS

The best and most consistent advicethat packagers who have switchedto slipsheets can offer those consid-

CALIPER (pt) 50 60 70 80MD 340 414 468 511CD 148 198 216 221

26

Packagers Ready?

ering the conversion is to studytheir own distribution system indetail, including incoming ship-ments and those receiving theirloads. Those experienced are of onevoice in emphasizing that each sys-tem is different, so what works inone place may not apply to another.

Among the major justifications forslipsheet use have been:

■ Low unit cost—between 40¢and $2, depending on thetype and design.

■ Lightweight—about 3 lbs vsperhaps 75 lbs for wood.

■ Smaller size permits perhaps10% to 12% more cube infreight carriers. Being thinnerand lighter, some 12,000 slip-sheets can be shipped in thesame truck trailer that carriesonly 430 pallets.

■ Slipsheets aren’t consideredas dangerous a fire hazard aswood pallets and may bestored indoors where they canbe protected and kept clean.They eliminate the expense ofrepair crews and other main-tenance chores long a part ofwood pallet use.

Negatives exist also. Cost of equip-ment has been cited as the numberone obstacle to wider slipsheet use.The shipper must be equipped tomove slipsheeted loads onto rail-cars and truck trailers. Truck driv-ers often unload their own trailersonto receiving docks, so they mustbe trained in the new methods andequipment. And, of course, thereceiver must be equipped to dealwith slipsheets.

Will slipsheets ever replace pallets?That depends largely on who’s talk-ing. In many shipping and receiv-


Reprinted with permission ofModern Packaging, apublication of Morgan-GrampianPublishing Co., April, 1979 issue.

ing areas, slipsheeted loads arestored on pallets to keep them offthe floor.

Further, certain heavy loads thatmight damage the paper units, orloads with high moisture content,may have to continue riding onwood. Pallets will also be used indistribution systems where conver-sion isn’t cost effective.

In short, the slipsheet is here tostay, but it will have to share thenation’s physical distribution chan-nels with the wood pallet for a longtime to come.

27

Packagers Ready?

ARE SLIPSHEETS FOR YOU?Deciding the relative merits of pallet and slipsheet systems requires a detailed analysis of the costs associated with each,as they would apply to a given company’s needs. Cascade Corporation, which produces equipment for each system, sug-gests the following points be included in such a study.

PALLETS

1. Number of units shipped.2. Cost per pallet.3. Average pallet life.4. Number of pallets owned.5. Cost of money in percent.6. Average weight of outbound

freight.7. Weight of pallets.8. Cost of pallet return freight.9. Total pallet repair cost annually.

10. Time required to store andremove loads from storage.

11. Time required to stage and load with pallets.

12. Labor rates.13. Time to unload and return

pallets, inspect, sort, and administrate.

14. Fire insurance for pallets.15. Pallet shortages due to float.16. Space occupied by pallet,

versus that used for product.17. Damage caused by pallets—

broken deck boards, over orunder hand of product,nails, etc.

18. Sanitation: The FDA inspectspallets for rodent leavingswith black lights.

19. Pallets returned inferior tothose shipped.

20. Storage space required.21. Potential future shortage of

pallets and increasing costs.22. Safety.

SLIPSHEETS

1. Number of loads.2. Cost of slipsheets.3. Cost of slipsheet dispenser.4. Slipsheet dispenser average life.5. Number of slipsheet dispenser

units required.6. Cost of push/pull equipment.7. Load push/pull average life.8. Number of load push/pull

units required.9. Time to store and remove load

from storage.10. Time to stage and load.11. Labor rate.12. Cost of captive pallet.13. Number of captive pallets.14. Average life of captive pallets.15. Repair of captive pallets.16. Storage space required.

28

A Case For Slipsheets

MAKING A CASEFOR SLIPSHEETS

They’ve been the RodneyDangerfield of the GroceryIndustry for years. However, newdevelopments may win newrespect for slipsheet technology.

By Tom Andel,associate editor

What’s 48 x 40 inches, has ninelegs, weighs 30 pounds, is flat ontop, protects whatever is placed onit from damage, is reusable andrecyclable, and costs only $3?Nothing – yet.

Such a shipping platform is theHoly Grail of shippers in manyindustries, particularly grocerymanufacturers. In fact the GroceryManufacturers of America (GMA),the National American WholesaleGrocers’ Association (NAWGA), andthe Food Marketing Institute spon-sored studies analyzing various pal-let makes and designs, looking forthe best one.

This search has received a lot ofpress recently, but a small group ofshippers feels the committee isoverlooking an old but proven plat-form – slipsheets.

Over the past decade, slipsheetshave been relegated to a narrowniche in the food industry – unitiza-tion of mostly lightweight, bulkyloads during long haul transport.Horror stories about stacking dam-age and the cost of the push/ pullequipment needed to handle slip-sheeted loads kept this medium’sgrowth in check.

“The pallet committee estimatesthat 15% of grocery distributors areprepared to take slipsheeted

loads,” says SamCaufield, section manag-er with Procter &Gamble and member ofthe Pallet Subcommittee.“In thinking of alterna-tives to the GMA pallet,slipsheets were nevertaken very seriously. Nomatter how you cut it, allproduct ends up on apallet in a rack, regard-less of how we handle it internally.We take on the system the cus-tomer uses. The common denomi-nator for the grocery distributor isthe pallet.”

Grocery shippers taking issue withthis opinion formed a users groupto continue a dialog about slip-sheets with their customers. Thisad hoc committee includes repre-sentatives from General Mills,Coors, Ralston-Purina, Nestle,Quaker Oats, Lipton, Pillsbury,Kelloggs, Kimberly-Clark, andHunt-Wesson.

“Some in the food industry wouldlike to see slipsheets go away,” saysBen Janson, vice president anddirector of logistics/customer serv-ice for the Grocery Products Groupof Ralston-Purina.

“We’re not trying to force slipsheetsdown everybody’s throat,” he adds,“we just don’t want to see restric-tions until some satisfactory alterna-tives emerge. So far they haven’t.”

PLASTIC DESIGNS

Companies in the slipsheet usersgroup are working on ways toovercome the problems associatedwith slipsheets. Coors, for exam-ple, used itself as a guinea pigwhen it started experimenting withplastic slipsheets.

Eighteen years ago, Coors shippedits beer on wooden pallets. Theyhad a pallet exchange program, butthe more good pallets they shippedout, the more damaged, low qualityreplacements they got back. Nextthey tried paper slipsheets, butmoisture quickly made them unus-able. Then they experimented withplastic extrusions and started usinga plastic copy of the paper slipsheetthey had used. That worked untilCoors started making their cansfrom lighter, thinner aluminum.

“As we lightweighted our cansmore and more, the weak point inthe chain became the slipsheet,”says Bill Longaker, business devel-opment manager for GoldenTechnologies, a Coors subsidiary.“We discovered as we shipped ourcans down the road, the first tierwould collapse. We learned weneeded more cushioning.”

Their next alternative was acorrugated plastic slipsheet. Thisprovided a modicum of shockabsorption, so they used this designfrom 1986 to 1988.

Further experimentation yielded the

Apple Computer's requirement thatoverseas trading partners ship to them

on slipsheets cut container unloadingtime from seven man hours per

container to 45 minutes, using lift trucks with push/pull attachments.

29

INTEGRATEDPACKAGING SYSTEMS

Slipsheets play an important rolein an integrated packaging sys-tem. Consultant Charles W.Ebeling includes a chapter on“Unitized Shipping on Slipsheets”in his book Integrated PackagingSystems- for Transportation andDistribution. Other chapterscover clamps, bulk containertransport, and case histories invarious industries.

The book is available for $89.75in the U.S. and Canada, &$107.50 in all other countries.Contact: Marcel Dekker, Inc.,270 Madison Ave., New York, NY10016, (212) 696-9000


design they use today – a vacuum-formed slipsheet with small spheri-cal dimples arranged in a close pat-tern across the sheet. Longakersays this design provides morecushioning than the corrugateddesign did. The design proved sosuccessful, Golden Technologieswas formed in 1989 to market thedesign outside the company. Theydidn’t find a wide audience.

“Not everyone needs a platform thatcan carry 3,000 pounds,” saysLongaker. “We move 3.5 millionloads that size every year. Thedesign was overkill for many. If theydidn’t recover the slipsheet, they’dlose money.”

Golden Technologies developed alighter-weight, 20-30 mil slipsheetmade of polyethylene instead of theprevious polypropylene. Longakersays the new design provides abetter return on investment. To addto its cost-effectiveness and live upto environmental concerns,Longaker says his company will buy

back every slipsheet his companymanufacturers, at a price he says isgood for both the user and GTC.

ROI REQUIRES EDUCATION

Slipsheet critics say return on invest-ment gets stifled by the expensiveequipment necessary to handle slip-sheets. There are also sticky sideissues. Who should operate theequipment – the carrier or the receiv-er? Who’s responsible for damagescaused by improper operation? Whatif the carrier is left waiting while slip-sheet handling equipment is tied upelsewhere at the receiver’s dock?

The Clorox Company overcamethese stumbling blocks by doing alittle research and taking the time totrain its people in slipsheet han-dling. Clorox moves over a mil-lion unit loads a year on slip-sheets. Sixty percent of thoseslipsheets are plastic. Cloroxengineer Bill Short attributesslipsheets’ image problems to alack of user education.

“We found that properly trainedlift truck drivers can handleslipsheets with the same speedthey handle wooden pallets,”he says. “In our tests we’vefound that with hydraulicallyadjustable platens you couldpick up a slipsheeted load, takeit off a truck, then put it on apallet. You can then use thesame truck to pick up that pal-letized load and do what youwant with it. The time differen-tial (between slipsheet and pallethandling) is not significant.”

Short believes there’s a trend in thegrocery industry toward high-risewarehouses using slave pallets intheir racking systems. He sees slip-sheets as playing a logical role inthat trend.

“If you’re going to have to put aunit load on a slave pallet, why notput a slipsheeted load on it andsave 6 inches of stacking height?”

Even the most ardent slipsheet pro-ponents admit that much work needsto be done to make slipsheets amore attractive unitizing alternative.

“The material handling industry hasto come up with an economical wayto unload slipsheets,” says BillShrack, manager of field distribu-tion for General Mills. “The cost ofa big lift truck with an attachmenthas been an impediment. One alter-native could be a walkie stackerthat grips and slides under slip-sheets. So far, the industry hasn’tput the resources into this technolo-gy. Technically it shouldn’t be hard.”

The costs of converting to slip-sheets vary, but ballpark figuresinclude $20,000 for adapting a pal-letizer to slipsheets and $7,000 to$10,000 for converting lift trucks.

..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...........................................................................................................................................................

.....................................................

.................

...........

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. . . . . . . . . . .

............

......

......

...

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Golden Technologies’ vacuum-formedplastic slipsheet features closely-spaced

spherical dimples which provide extraload cushioning during transport.

30


Golden Technologies’ Bill Lonakeris working on a more attractiveconversion option.

“We’re involved in developing ahand-operated slipsheet handlingdevice, “ he says. “By next year we’llhave a more affordable means ofhandling slipsheets. The cost wouldbe roughly the same as it would beto convert a lift truck. Plus, youwon’t need certified operators.”

NEW APPLICATIONS

Slipsheets have gained proponentsin non-grocery applications inrecent years. Merchandisers areasking their suppliers to slipsheetproducts ranging from small light-ing fixtures to cement. Ed O’Mara,product manager for Union Camp,a slipsheet manufacturer, sees greatpotential for slipsheets in third-world countries.

“This is new technology to them,”he says. “With the acceleration ofcontainerized freight through thisdecade, the slipsheet lends itselfvery nicely to loading and unload-ing. They can just put the slipsheeton the floor of the vehicle and man-ually build the loads using inexpen-sive labor. Slipsheets don’t take upspace or add weight, so they haveno impact on freight costs.”

Four years ago, Apple Computerwatched what was happening withslipsheets in the grocery industryand adapted it to their overseasoperations. They also watched whatPanasonic was doing with theirslipsheeted shipments to the U.S.Apple combined these lessons andcame up with a system in whichthey not only ship on slipsheets, butreceive on them as well.

“We went back to the Far East andtrained our suppliers to use slip-

sheets,” says Nigel Johnson, U.S.logistics manager for Apple. “Nowwe receive slipsheeted loads rightfrom our overseas suppliers.” Aftertheir first year of using slipsheets,Apple cut its freight costs 20%,translating to an annual savings of$1 million. They also reduced laborby 75%, saving an annual $500,000.A 78% reduction in pallet costsbrought another $500,000 savings.

Now in their third year using slip-sheets, Apple estimates 1991 sav-ings to be between $3.5 million to$4 million.

Using computer programs, Appleevaluated the size of the carton theyused and established the ideal unitload to improve cube utilization.The pallets they purchased over-seas took about 5% to 10% morespace and cost from $25 to $30each. Also, by switching to slip-sheets Apple cut the time it took tounload ocean freight containersfrom six man-hours down to 30minutes – a key benefit, consider-ing the trend toward rising laborcosts in Pacific Rim countries.

In the U.S., Apple selected carriersin various regions that could han-dle their products in full unit loads,using lift trucks equipped withpush/ pull attachments. This allevi-ates the damage caused by individ-ual-case handling.

“Our competitors are asking us toshare our successes with them, andthey are looking at going to slip-sheets,” says Johnson. “At one timewhen the profit margins were therefor our products, cost wasn’t asmuch of an issue. Now competitionis up and margins are down andlogistics is getting attention in theelectronics industry. We went toslipsheets for the same reasons the

grocery industry did – to reducelogistics costs.”

In the next edition of IW &D, we’lllook at trends in pallet design andhandling. As this edition goes topress, the food industry’s PalletSubcommittee is looking at somenew pallet prototypes. We’ll tell youwhether the industry is any closerto finding its Holy Grail.


GROCERY DISTRIBUTIONSeptember/October 1991 Issue

Productivity in PalletManagement. “Chain details

experience with nationalpallet pool program.”

Page 22

“With pallet manufacturing con-stituting the second largest useof sawn lumber in the U.S., thepotential for savings in lumberis enormous.

In 1988, seven million boardfeet of lumber were used inconstructing white pallets.Studies indicate that as muchas 2/3 of the lumber usedmaking these pallets is now, ayear and a half later, clogginglandfills nationwide.”

31

Save Air Freight Cost

SLIPSHEETS SAVE WEIGHT& COST IN THE AIR

As much as 51 pounds of excessweight flies with nearly every airfreight shipment in the form of awooden pallet. Slipsheets haveproven themselves on the sea andnow take to the air.

By C.W. Ebeling

In February 1991, the largest aircargo plane in the world, theRussian Antonov AN225 Mriya, land-ed at Bradley Field in Hartford, CT,on its first visit to the U.S. It wasthere to pick up 250 tons of medicalsupplies and equipment destined forthe victims of the Chernobyl nuclearplant disaster. Though loaded to itsfull 250-ton capacity, it could havecarried approximately 10% moremedical supplies.

In addition to medical supplies, theMriya carried approximately 25tons of wood in the form of 672standard 48" x 40" pallets.

The AN225 is like a flying ware-house. Built in the Ukraine, it is276 feet long and has a wingspanof 290 feet. Powered by three giantturbofan engines underslung oneach side, it is similar in appear-

ance to the four-engine LockheedC5 Galaxy. How-ever, its maximumtakeoff weight of 1,322,770 poundsis significantly higher than the840,000 pounds of the C5.

The fuselage of the AN225, like theC5, is hydraulically lowered tofacilitate loading. Its nose cone isrotated upward over the flight deckand a ramp is extended to theground for lift truck and othervehicle traffic.

For the Chernobyl mission, lifttrucks carried stretch-wrapped,palletized unit loads intothe cargo bay and stackedthem three high, five rowsacross. The interior of thecargo aircraft holds theequivalent of 16 40' ISOocean containers – or upto 672 standard pallet-loads. With each palletaveraging 75 pounds, thetare weight of that manypallets accounts forapproximately 10% of theplane’s 250-ton payload capacityand occupy 10% of the availablecargo bay space.

RATIONALIZING UNIT LOADS

Turnaround time on the ground is

critical to the economic utilizationof costly cargo aircraft – and theAN225 is reportedly priced at over$200 million. Unitized handling ismandatory for fast loading and un-loading. But because of its weightand bulk, the pallet seems incon-gruous to air freight transport.

One company which recognizedthis is Micropolis Corp. A manufac-turer of high capacity computerdisk drives and data storage sys-tems, Micropolis ships 95% of itsproducts internationally by air. It

maintains a manufacturing site inSingapore and distribution loca-tions throughout the U.S. andEurope. Air freight is justifiablebecause it reduces inventory levelson high-value products while pro-viding more flexibility in meetingcustomer demands.

While it could take three to fourweeks to move an ocean containerof product from Singapore to theU.S., customers are looking for fastresponse to orders and just-in-timedeliveries. Air freight shipments

The Antonov 225, with its 250-ton cargocapacity, is like a flying warehouse. Itoffers a good example of the potentialsavings when slipsheets replace pallets inair freight – a weight and volume reductionof approximately 10%

Elimination of the pallet base allowedMicropolis to add a fourth tier of

product to air shipments.

32

Apple Computer’s slipsheet han-dling operations at Cupertino, CA.What they saw there helped themvisualize how to adapt the methodto an air freight program. Sincetheir products were hand loadedonto pallets at Singapore the imme-diate plan was simply to place aslipsheet onto each pallet and thenbuild the unitload on it.

The unitized loads on slipsheets

THE FUTURE FOR SLIP-SHEETS IN AIR TRANSPORTThe use of slipsheets for inter-national air cargo shipmentscan be expected to multiplyrapidly now that the practicalityof adapting them to air freightsystems has been demonstratedby Micro-polis and now that airforwarders are installingpush/pull attachments on theirlift trucks. Freight shipperswho ship on large cargo planessuch as the Antonov 225 andthe C5 Galaxy that carry mostlymilitary supplies, or those whoship in plane-load quantity mayalso find that the slipsheet alter-native can be adapted toimprove payloads and reduceshipping costs for their unitizedfreight shipments.

from Singapore can actually arrivethe same day in the U.S. because ofthe international date line.

Micropolis’ existing shippingmethod called for product to beunitized three tiers high on woodenpallets and then overwrapped withstretch film. The freight forwarderat the airport transferred the pal-letized loads onto LD7 or M1 aircargo container shipping bases forloading in widebody jets.

The typical net payload of productsin each unitload was 932 pounds –to which the tare weight of the pal-let added another 55 pounds.Clearances within the cargo bayskept pallet tiers three high.

SLIPSHEET ALTERNATIVE

This began to change after BillFaridan, corporate packaging engi-neer at Micropolis, attended apackaging conference sponsored bythe Institute of PackagingProfessionals (IOPP). There helearned of Apple Computer’s suc-cess shipping computer productson slipsheets in ocean containersfrom sources throughout the world.(See T&D’s 1988/89 PresidentialIssue, pg. 30.)


Apple had converted its foreignsuppliers to slipsheets and had themethod fully implemented by

1990. Annual savings hadtopped $3 million.

The slipsheet unitization methodmade sense for internationalshipments in ocean containers,and it seemed it would provideeven more benefit in air freight.The slipsheets weigh fourpounds and so add very little tothe gross weight of a shipment.They also occupy a negligible

amount of space under unit loads.In addition, slipsheets cost far lessthan a pallet and are easier to dis-pose of on the receiving end.

Raridan identified a few concernsconnected with the integration ofslipsheets into an air freight system:

■ Lift trucks at Micropolis’shipping andreceiving loca-tions – as wellas those operat-ed by freight for-warders at theairports – wouldhave to beequipped withpush/pull hand-ling attachments.

■ Lift truck operators would re-quire special training tobecome proficient in operat-ing the push/pull attachmentsand with slipsheet handlingmethods.

■ Resources would have to beprovided to set up and coor-dinate the entire slipsheet program.

To build further knowledge aboutslipsheets, Micropolis’ logistics sys-tem planners subsequently visited

Micropolis unitizes loads on slipsheets atits Singapore plant and places the loadon a pallet for the trip to the airport.When it arrives in Los Angeles, it is againplaced on a pallet for handling ease.

Slipsheeted loads are placed on LD7air freight bases for air shipment and

then removed at the destination.

33


would remain on the pallet for thetrip to the airport. There thefreight forwarder would installpush/pull attachments on the lifttrucks to transfer the loads off thepallets and onto the air cargo con-tainer bases. The empty palletswere then returned to theSingapore plant for reuse.

Correspondingly, the freight for-warder on the receiving end wouldinstall push/pull attachments for thelift trucks at the airport in order toremove the slipsheet loads. In thebeginning the loads would be trans-ferred back onto pallets for truck-ing to the Micropolis facility atChatsworth, CA, or directly to cer-tain customer destinations.

For the second phase of implemen-tation, push/pull attachments wouldbe installed at the Micropolis ship-ping and receiving facilities inorder to eliminate the need for pal-lets in the shuttle hauls to and fromthe airports.

A critical accomplishment in theprogram was gaining the agreementof the freight forwarders to pur-chase push/pull attachments for thelift trucks and to train their opera-tors to use them.

CHANNEL PARTNERS AGREE

Micropolis’ project managers wentto Singapore for meetings with theiroperations people and the freightforwarders. It was important toacquaint all who would play a rolein the project with the slipsheetsmethod. Tours of Apple Computer’sSingapore facilities were arrangedso that all involved could observethe slipsheet handling methods andequipment firsthand.

In the plan that evolved, packagingwas redesigned as necessary to

make best use of slipsheets.Raridan clarified that the designchanges which were eventuallymade were related to the heightdimension of the shipping cases.This was necessary in order tooptimize the use of the space thatbecame avail-able when the palletswere removed from under theloads. Previous packaging designchanges had already been made toachieve efficient configurations forthe 48" x 40" surface dimensionsof each unitload.

Micropolis began initial air ship-ments of slipsheet-unitized loads inJuly 1991. Airport transfer opera-tions were not as difficult as antici-pated. Replacement of the woodenpallets with paperboard slipsheetsreduced the tare weight approxi-mately 51 pounds per unitload.With pallets removed, it was possi-ble to increase the number of tiersof product on each unitload fromthree to four and still stay withinrequired height clearances.

The load density increaseamounted to 33%. A typical ship-ment is an LD7 space configura-tion increased from 2,325 kb(5,126 lbs.) to 3,100 KG (6,834lbs.). Translated into cost savings,Micro-polis projects an annualnet savings of $342,000 based oncurrent volume.

According to Bill Raridan, thecompany intends to integrate theslipsheet air freight method into itsentire global logistics system. It willinclude shipments from theirBangkok manufacturing centers aswell as Singapore and will encom-pass destinations in the U.S. andEurope. Raridan adds that all ofMicropolis’ new shipping cartonsand systems are now being

designed for slipsheet use.Slipsheet use is being extendedfrom finished products to compo-nents and assemblies worldwide.Containers intended for UPS andother parcel carriers have alsobeen redesigned so they can behandled unitized on slipsheets atMicropolis facilities.

Bill Schubne., manager of corporatelogistics at Micropolis, summarizedthe success of their program as theresult of the cooperation and jointeffort of the airlines, the freight for-warders, and Micropolis. Importanttoo was the technical support of theslipsheet supplier and the push/pullattachment vendor.

Ebeling is an internationallogistics consultant and regulareditorial contributor to T & D. He is author of the bookIntegrated Packaging Systems forTransportation andDistribution published byMarcel Dekker Inc., New York

Inside Global Logistics, a specialsection of T&D February 1992 T&D

34

German Perspective

GERMANY SAYS NO TONORTH AMERICANPALLETS!

What happened to the good olddays when a pallet company didnot have to worry about what hap-pened to a pallet after it wasaccepted by a customer? The pic-ture is shifting, but just how far isit going to change?

In some parts of the world, mostnotably Germany, the picture isintense. The Germans used to land-fill or incinerate unwanted woodenpallets, including North Americanstringer pallets. This is no longerpermitted. Germany passed a newrecycling law which is generatingreal concern. According to BrianMcGregor, Assistant Chief of theInternational TransportationBranch, USDA, it is causing a stirthroughout Europe, includingGermany, as well as with U.S.exporters. The overall thrust of thislaw is that companies which origi-nate a packaging product whicheventually ends up in the solidwaste stream will be held responsi-ble for disposing of that packaging.This includes wooden pallets!

Germany’s Packaging Regulationpassed on April 19, 1991; the newpackage recycling requirementswill come into effect in three stages.The first stage started December1, 1991. At that time, manufactur-ers and distributors were requiredto take back all used transportationpackaging. This includes pallets,crates, styrofoam containers, andother packaging forms used to pro-tect goods during shipment.Starting on April 1, 1992, manu-facturers, distributors and retailerswill have to accept back all second-

ary packaging, which includescardboard boxes and blister packs.Sounds like a good April Fool’sjoke, doesn’t it. Starting onJanuary 1, 1993, retailers, distrib-utors and manufacturers in turn willhave to take back sales packaging,which refers to packaging needed totransport and hold the goods untilconsumption. This includes cans,foil wrapping, plastic containers andcardboard packages.

We have heard stories that U.S.exporters are going to have to shipon Europallets or pay for havinggoods transferred to a Europallet,pay for the Europallet, and pay tohave the pallet shipped back to theU.S. for disposal. There is a greatdeal of confusion about what thisnew packaging legislation willultimately mean. It is our under-standing, however, that Germany isenforcing its pallet rule.

Under the law, the business entitybring imported goods across theGerman border, be it a German orforeign form, is responsible for therecycling or reuse of packaging asdescribed by the ordinance. Eitherthe firm must take back its packag-ing or pay a German firm to dis-pose of it in accordance with thelaw. German government officialsexpect foreign firms to follow thelatter course.

Those U.S. firms which ship theirfinal product from the U.S. toEurope and their importers face amajor problem. This problem is aresult of the different shipping pal-lets used by American andEuropean exporters. Europeansuse a reusable 80 x 120 cm“Europallet,” while Americans usethe one-way 100 x 120 cm “seapallet.” In the past, these sea pal-lets were simply thrown away when

the goods reached their final desti-nation. The new packaging regula-tion, however, eliminates thisoption. In the future, all importedgoods are likely to be transferredfrom sea pallets to Europallets atthe German port; sea pallets willnot be allowed to leave the portarea. Theoretically, then, the seapallets will simply sit at theGermany port until they are used byGerman exporters or periodicallyloaded empty onto U.S. boundships. German importers will wantto pass on the cost of the secondoption to American exporters.

One might suggest that U.S.exporters simply switch to aEurostyle pallet. This may not be aseasy as it sounds. The 80 x 120 cmpallet roughly corresponds to a 32 x48 North American pallet. U.S. boxesmay not properly stack on this palletsize. In addition, the shipping con-tainers used to ship to Europe aredesigned to fit 48 x 40 pallets. Thesmaller Europallet will leave a greatdeal of room inside shipping con-tainers for products to shift, allow-ing for potential product damage.

The bottom line is that one-waywooden pallets are not going to beacceptable in Germany. The otherEC countries are studying theiroptions and considering what kindof similar action they, too, will take.They generally do not like theGerman law, at least partiallybecause many shippers find the 48x 40 size to be preferable over the48 x 32 pallet. The U.S. may finditself having to ship on Eurostylepallets. Block pallet talk is every-where today. As the world shrinksand seeks uniformity to reduceshipping costs, block pallets maywell become the norm. For NorthAmerican pallet manufacturers who

35

German Perspective

are used to stringer style pallets,this may all seem like so muchfolly. Make no mistake about it,however, there are some very goodreasons why block pallets maybecome the pallet of choice forinternational markets. This alonewill cause U.S. firms to move inthat direction as they seek toexpand their export opportunities.

Readers may be sensing anotherdirection to this editorial. Thiswhole scenario opens the door thatmuch further to pallet pools,including pallet rental options.

Alan French, GKN Chep Ltd. UK.wrote in the September 1991Eurofruit magazine, “The topferlegislation (recycling law) inGermany is encouraging the marketto move towards standardizationand the use of returnable equip-ment. This is precisely the businessin which Chep specializes.”

What does this mean in NorthAmerica? Brian McGregor of theUSDA suggests. “U.S. exportersshould get in touch with their buy-ers. Inform them what is going onand ask what they suggest bedone. Get the official representa-tive of the U.S. pallet industry totalk with U.S. Dept. of Commerce,U.S. Dept. of Agriculture, and foreign services.”

At this point there is no reason todo anything rash. But it is time tostart acting by talking to the rightpeople in positions of influence.

GERMANY GETS TOUGHON PALLET DISPOSAL

Germany has adopted a newenvironmental packaging law that ismaking headlines throughout theworld. The law requires companiesthat ship products into Germany to

take back and recycle the resultingpackaging waste. The new law isbeing touted as tougher than any-thing introduced in any other coun-try in the world. The reason is thatlandfills in Germany are likely to fillup within five years.

The new law has many companiesaround the world up in armsbecause of the substantial increasein costs to export to Germany. Thelaw has also been criticized fordiscriminating against smallexporters and interfering with thesingle European market since itprevents the free movement ofgoods across borders.

The Timber Packaging and PalletConfederation (TIM CON) locatedin the United Kingdom, estimatesthe cost to British industry of com-plying with the law could run intomillions of pounds. “One can onlyask whether this is simply a case ofill-thought-out legislation or some-thing more sinister.” said AlainSkelding, a TIMCON official. “Ifother member European states takesimilar action, we can say farewellto the single market before it haseven begun.”

Germany’s new law will be imple-mented in three stages. The firststage began December 1, 1991,and affects transport packaging anditems such as wood pallets. In April1992, stage two will become effec-tive and covers intermediate pack-aging such as cardboard boxes.And beginning January 1, 1993, allpackaging will be covered, evenitems like yogurt containers andbutter wrappers.

Manufacturers and distributors ofthe finished product will be respon-sible for their own packagingwaste. They do not necessarily haveto take it back themselves, but can

contract the disposal to a recyclingfirm located in Germany.

A similar trend is developing in theU.S. A 1988 report to Congressfrom the Environmental ProtectionAgency (EPA) indicates that since1978, 70% of the 14,000 operatinglandfills have closed. With the dropin the siting of new landfills thathas occurred over the past 10years, there are now less than6,500 landfills currently operating.

EPA projects that more than 2,000of these active landfills will close by1993. Four states – Florida,Massachusetts, New Hampshire andNew Jersey – will close virtually allcurrently active landfills by 1998.Across the U.S. industry leadersfear that as more and more land-fills close, lawmakers will see fewalternatives to creating legislationsimilar to Germany’s new law.

(Editors Note: If you have acustomer that is exportingpalletized goods to Germany,they need to make arrange-ments for the pallets to betaken back or disposed of inGermany. One firm that canbe contacted which has morethan 600 partners to handlethe removal of packaging fromGermany is (Interseroh AG”.Contact Rudolf Trum orWolfgang Jansen at:Industriestrabe 11,D-5000 Koln 90(Porz), Germany,Phone (0 22 03) I 7040Fax (02203) 17 04 17

36

Pallets & Pests

U.S. TELLS IMPORTERS:PESTS ARE ‘UNPALLETABLE’USDA to Impose Certification Burden

By William DiBenedettoJournal of Commerce Staff

SEATTLE—On Wednesday, animporter of, say, sewing machinesor refrigerators will have to startworrying about tree bark and bugs.

That’s because inbound pallets –those ubiquitous flat wooden crateson which just about any type ofcargo is secured for shipment –must be certified as “totally free ofbark and apparently free from liveplant pests” under regulations issuedby the U.S. Department ofAgriculture’s Animal Plant and HealthInspection Service (Aphis). Othertypes of wooden packing materialsalso are subject to the new rules.

Certification that a pallet is barkfree and pest-free must be part ofone of the import documents, suchas a manifest, bill of lading or gen-eral permit. If not, the entire ship-ment will be delayed while thecargo is either shifted to a cleanpallet or the suspect pallet is fumi-gated or otherwise treated.

No one knows how many palletsare used in the import process andthus how many will need to be cer-tified. But there were about 400million pallets built in the UnitedStates last year, so there are proba-bly billions of pallets in world com-merce, said Sam Baker, director oftechnical services for the NationalWooden Pallet and ContainerAssociation in Alexandria, VA.

“About 98% of everything we usewas on a pallet at some point,” Mr.Baker said.

While Aphis has indicated that therule won’t be enforced immediate-ly, compliance at any point couldmean substantial additional cost.And that’s not playing too well withcustoms brokers and freight for-warders.

Pallets have always been subject toinspection for pests. But putting theburden of certification on importersis new. How, for example, is animporter of widgets – who may noteven know whether a shipmententered the country on pallets, andwho probably has no direct know-ledge of their source and conditionin the transportation chain – tomake the required certification?

“An importer sometimes doesn’tknow if the stuff is on pallets or notand has no idea where the woodcomes from,” said NormanElisberg, owner of LafayetteShipping Co., a licensed customersbroker in Englewood Cliffs, N.J.“And they don’t know what Aphisis.

“It would be like you and I certify-ing there are no cockroaches onMars,” he said. Brokers, who pre-pare the import documents, andshippers “Often don’t know if thereare pallets involved in the ship-ment,” said Mr. Elisberg.

Verifying the certification state-ments could mean “stopping con-tainer after container. An awful lotof cargo could get delayed. I agreethere’s a problem that Aphis wantsto address, but the solution is adisaster,” he said.

Mr. Baker, however, said certifica-tion is a “Logical extension to theinspection process.”

“It’s not asking too much to expectthat pallets be free of bark andbugs,” he said.

The Aphis rule is not very novel ordifferent from what other countries,such as Japan and Australia,require, “so this shouldn’t come asa massive surprise,” he said.Fumigation and heat treatment are“common-sense industrywide prac-tices that are well known, if notalways used. Some people mighthave to clean their act up andspend more money if they have toupgrade their pallets.”

Fumigation can delay a shipmentfor a week to 10 days, and fumigat-ing pallets is a 40-foot containercan cost $900 to $1,400, depend-ing on whether the cargo has to beunloaded and reloaded, said CrystalOsborne, president of A.H. Marzolf& Co., a Seattle brokerage and for-warding firm. “Yes, I do have con-cerns. It’s definitely going to havean impact.” Ms. Osborne is alsopresident of the CustomhouseBrokers and International FreightForwarders Association ofWashington State.

Richard Orr, an operations officerfor Aphis in Riverdale, Md., saidthere will be a grade period of up toa year to make sure everyone under-stands the certification requirement.

“We don’t anticipate any problems,but that’s probably naive,” he said.

“We do not intend to precipitouslystart enforcing the rule,” said JimFons, a senior operations officer.Delays will occur when bark or livepests are present, he said, but thatis already the case.

Once the rule is fully enforced,though, failure to have the certifica-tion could result in criminal andcivil sanctions.

The pallet-certification requirementis a part of a larger, more complex

37

Pallets & Pests

regulation that finalizes interimstandards for importing logs, lum-ber and items such as wood chips.It includes specific requirements –heat treatment and fumigants – forimports from all countries exceptCanada and Mexico.

Requiring importers to have certifi-cation is the “hang-up,” said FredHigdon, director of import compli-ance for Fritz Cos. in San Francisco.“They went after the importer, evenif they have nothing to do withwood packaging. The burden is onthe importer to tell shippers to usebark and pest-free pallets.”

Still, Mr. Higdon said, delayingenforce-ment will lessen the imme-diate effect of the rule. “Perhaps itwill only be a speed bump,” he said.

Mr. Baker said he did not view theAphis rule as a nontariff trade bar-rier, “although someone may beunhappy and want to make thatclaim. It’s not taking effect asthough a guillotine will fall. Therewill be time for people to makethe adjustment.”

Reprinted from The Journal of Commerce

38

Freight Processing Centers

FREIGHT PROCESSINGCENTERS: LOGISTICS’MISSING LINK

Enigmatic Asia exemplifies theneed to bring modern logisticsto emerging nations. Third par-ties can provide the answer—and overcome infrastructurelimitations.

By C.W. Ebeling

Beijing, China today is a city ofcontradiction. A bustling center forcommerce, it is the hub of thenation’s railway and airline net-works. China’s tallest hotel (52 sto-ries), and its tallest TV Tower withan observatory (1,300 ft. high) arerecent additions to the city’s sky-line. Yet, down on the busy streets,thousands of three-wheel pedalvehicles still deliver retail productsand other goods and materials.

To Western observers, the contrastof primitive freight handling andtransport methods amidst citieswith modern tall buildings andstate-of-the-art communicationsfacilities is bewildering. Such,however, is the dilemma of logisti-cal technology in many countriesin Asia.

While highly visible in China, thisenigmatic condition is not exclusiveto any particular part of the world.The development of physical distri-bution methods and systems haslagged behind the technologicalprogress made in other fields inmany countries. Government andindustrial management prioritiesare given to the development ofother areas of commerce andworld trade. The products arepackaged, shipped, and distributedby whatever means are expedient tothe individual shipper.

Unfortunately, such traditionaltrade practices do little to improvethe physical logistical methods andcost efficiencies for the movementof goods and materials in anexpanding global economy. Third-party, independent companies thatspecialize in the development andapplication of new and innovativemethods of packaging, handling,shipping, controlling, and distrib-uting freight can contribute greatlyto logistics technology and help itto keep pace in a high-tech world.Norvanco International demon-strates the value of this approachin Asia.

On April 1, 1992, Norvancoannounced the opening of a new

kind of freight processing facility atSingapore. The facility, a three-story, 300,000 sq. ft. freight pro-cessing plant, is the consummationof a joint venture formed byNorvanco with Integrated AgencyPte. Ltd. of Singapore. It is operatedunder the name, Main DistributionServices Pte. Ltd.

It could be the prototype for similarfacilities throughout the world bythe turn of the century. The newfreight service center bringsadvanced technology to the plan-ning, preparation, loading, dis-patch, control, and delivery of con-tainerized freight throughout thelogistical process. The facility isequipped with state-of-the-art unit-izing equipment, stretch film wrap-pers, and lift trucks equipped withpush/pull attachments.

Norvanco International, headquar-tered in Kent, WA, provides a com-prehensive service package that, inaddition to the latest freight prepa-ration and material handling meth-ods, includes custom house bro-kerage, transportation and logistics

Pedal vehicles are well integrated intothe distribution systems of manyAsian countries.

Inbound cases at Norvanco’sSingapore freight processing centerare unloaded and moved to unitizersvia conveyor.

39


management, warehousing, value-added distribution (labeling, barcoding, serial number retention),quality assurance, and computerand communications support.

Norvanco does not manufacture aproduct. Its entire business is theapplication of state-of-the-art logis-tical methods. It is distinguished forits innovative developments such asINVENTECH, a computerized, real-time inventory control and trackingsystem, and its automated freighthandling operations at Kent and inLos Angeles, CA.

KEEPING PRODUCTIVITY UP

Few shippers, if any, in the develop-ing countries are capable of provid-ing their own in-house systems andequipment that the facility atSingapore provides. Even the largershippers in the less industrializedcountries have little incentive formaking expenditures to provide unit-ized shipping and mechanized han-dling across their docks. In mostcases, they have an abundant sourceof low-cost labor for handstackingoperations. Consequently, the bene-fits of unitized shipping and mechan-ical handling are lost throughout thelogistics process. The cost impact ofthis use of low-cost labor for handstacking is especially unfavorable onthe high-labor-cost receiving docksof developed countries as containersarrive with freight that must beunloaded by hand.

Pallets are not uncommon in manyof the developing countries but pal-letized shipping in ocean contain-ers is ordinarily avoided. The tareweight and the space taken up bypallets under the unit loads adds tooverall net shipping costs.

Palletless unitized methods such asslipsheets discourage most shippers

due to the cost of special equip-ment and the training required tooperate it properly. As a result, theslow, labor-intensive process ofhand loading and unloading is per-petuated.

The few large international ship-pers that have implemented theirown programs for shipping on slip-sheets have gained substantial costbenefits. As examples: AppleComputer saved millions of dollarsannually by eliminating the time-consuming and labor- intensivehand unloading operations at theirdocks. (See T&D PresidentialIssue, 1988/89 pp. 30-34)

Another company, Micropolis, inte-grated the use of slipsheets in placeof pallets for international airfreight shipments of their computerperipheral products and achievedsizable transportation cost savingsthrough the greatly improved loaddensities that resulted. (See T & D,Feb. 1992, pp. 53-55)

Both Apple and Micropolisenjoyed the shipping volumes thatenabled them to maintain in-housesupport for the planning, develop-ment, and implementation of theirslipsheet programs.

KEEPING COSTS DOWN

By channeling their exported prod-ucts through the new cargo pro-cessing facility at Singapore, allshippers can enjoy the benefits ofslipsheeted unitized shipping with-out investing in special equipment,trained personnel, or specializedadministrative functions at theirshipping and manufacturing loca-tions. Further- more, they need notchange their existing methods ofshipping outbound from their man-ufacturing plants.

Upon arrival at the freight process-ing facility, the most efficient unit-load patterns for the particularproducts are determined by com-puter. The cases are then trans-ferred onto a conveyor and taken tothe unitizing machine for forminginto compact unit loads on slip-sheets. The unitized loads are thenstretch wrapped and moved to thedock where lift trucks equippedwith push/pull attachments transferthem into the ocean containers.Some shippers may send theirproducts to the facility alreadyproperly unitized on pallets. Inthose cases, special machines areavailable to switch the loads fromthe pallets onto slipsheets.

The lift truck operators have beenwell trained and are skilled in theuse of the push/pull equipment.Loading time for the slipsheet unit-load method is less than one man-hour for each ocean container.That compares with five to ten man-hours for each container if loadedby hand. Since the new facility ismechanically equipped to load over100 ocean containers a day, severalhundred manhours are saved dailyin the logistical process on theshipping end and likewise can besaved at the receiving locations.

IMPROVING SERVICE

Shippers gain the advantage of hav-ing their products properly unitizedfor the highest load densities possi-ble along with the mechanizedloading and unloading capabilities.Ocean freight and material han-dling costs are thereby minimized.

The receiver is able to rapidlyunload the container by lift truck.The container can be turnedaround in less than an hour at thedock, thereby getting it back into

40


productive use sooner as well asfreeing up dock space at thereceiving location. The entire logis-tical process becomes much morecost efficient. Both large and smallcompanies can benefit from thisnew kind of third-party logisticsservice. One of Norvanco’s firstcustomers is the Japanese giantMatsushita (Panasonic).

Not all inbound containerized ship-ments are routed directly throughto the ultimate receiving locations.Norvanco’s service at its receivingcenters at Kent and Los Angelesincludes the consolidation of unitloads for routing to two or morefinal destinations. Slipsheeted loadsmight be removed from inboundcontainers and placed back ontopallets for final delivery to thoseshippers who prefer to receive theloads on pallets. When necessarythe unit loads will be broken downand smaller orders unitized orpackaged in large bulk containersfor final delivery. Fast response ispossible since the instructions forthe deployment of products enrouteto Norvanco’s terminals arereceived in advance through thecompany’s computerized in-transitinventory management system.

Cargo processing centers help ship-pers gain the benefits of state-of-the-art unitized shipping methods andfreight processing without the invest-ment in the required special han-dling equipment, communicationssystems, and trained personnel.

Norvanco’s new freight processingconcept could be the forerunner ofthe worldwide network of newfacilities of this kind. Visualize theexpansion of trade relations withcountries in the Far East such asChina, and with Russia, theUkraine, and the newer nations of

Eastern Europe. It could take manyyears to upgrade the freight han-dling and shipping methods of thethousands of shippers in thosecountries to the present day unitizedfreight handling methods of theWestern world. The availability ofthe new kind of cargo preparationand processing centers would pro-vide a channel through whichfreight can be shipped to the Westwith the most cost-effective packag-ing and shipping methods availabletoday. Freight processing centerscould in the future prove to be themissing links that are urgently need-ed to modernize global logistics.

C.W. Ebeling is an internationallogistics consultant and regularcontributor to T & D. He isauthor of the book IntegratedPackaging Systems forTransportation & Distributionpublished by Marcel Dekkerof New York.

41

Michael (Mike) Pregmon, Jr. isdirector of distribution forCitrus Central, Inc., Orlando,Fla. A graduate of PennsylvaniaState University, he holds aBachelor of Science degree inTransportation and Logistics. Inaddition, he has an MBA degreefrom the New York Institute ofTechnology. Prior to his affilia-tion with Citrus Central, Inc.,Mr. Pregmon performed as dis-tribution manager with theMcCormick & Co., Inc.,Schilling Division, Salinas,California. A member of a num-ber of professional and industryorganizations, Mr. Pregmon isalso adjunct professor, GraduateSchool of Business, NovaUniversity, Fort Lauderdale, Fla.

Cost ComparisonsSLIPSHEETS & PALLETS:A COST COMPARISON

The rising cost of wooden pallets,coupled with the industry’s reluc-tance to engage in a workablepallet exchange program, hasopened the way for more wide-spread use of slipsheets. Here, adirector of distribution examinesthe costs of the two systems, theirindividual strengths and weak-nesses and arrives at some con-clusions about the future use ofpallets/slipsheets in the food dis-tribution system.

By Michael Pregmon, Jr.,Director of Distribution,

Citrus Central, Inc.

The determination of whether pal-lets or slipsheets should be used isoften a difficult question con-fronting many distribution of mate-rials managers. There are manynotable advantages for using slip-sheets. Foremost of course is theextreme lower capital investment insupplies. Wooden pallets currentlycost approximately $7.50 each. Thecurrent price quotation for slip-sheets is 48.5¢ each. Let’s reviewsome other considerations.

Obviously, slipsheets are designedto be expendable once they leavethe shipping point. However, manyfirms reuse slipsheets within theirwarehouse operation. Experience

dictates that using wooden pallets isa better method for intra-plant/warehouse handling. But, to main-tain the unit handling integrity andcost savings, slipsheets are muchbetter in an open distribution loop(when shipping to customers orpublic warehouses, etc.). The rea-son for this is that it is often difficultand costly to handle and arrangefor the return of wooden pallets tothe original shipping point.

We have calculated an outright lossof approximately 15% of the palletswe release when participating inthe so-called “pallet exchange”programs. Further, of those whichare returned, 29.8% requirerepairs before reuse. Why are thesepercentages so large? There aremany reasons for this. But, princi-pally, two main explanations sur-face repeatedly.

All carriers recognize the financialbenefit of a revenue generatingback-haul. Empty pallets requirespace which can be utilized for rev-enue traffic. As a result, palletswhich may have been tendered to acarrier by a consignee in anexchange are often discardedsomewhere at the expense of rev-enue freight. This is particularlycommon with motor carriers whouse owner-operators. Repeatedclaims against the carrier for non-delivery of pallets only serves to

drive upward carrier costs andlikewise freight rates.

The high percentage for returnedpallet repair costs obviously resultsfrom the prudent action byreceivers. If pallets are to bereturned, needless to say the newand good pallets will be retained asmuch as possible and usually thosein questionable repair will beoffered for return. This in fact hasbeen one of the major challengesencountered by the National PalletLeasing Systems Incorporated


42

Cost Comparisons

(PEP) organized a few years ago.The problem of exchanging palletsof like quality is ever present.Because of the initial cost outlay forwooden pallets, most firms mustundertake a pallet repair programto extend the useful life of woodenpallets. This is a costly venture.

In the food industry, warehousecleanliness is imperative. We havediscovered a considerably greaterincidence of infestation with the useof wooden pallets. This is even moreprevalent when pallet exchange pro-grams in the distribution channelare entertained. Nevertheless, this isa greater concern in dry storagewarehouse operations than it is inrefrigerated warehouses.

A larger number of cases can beloaded into a rail car when usingslipsheets. Of the refrigerationequipped rail cars we have availableto us 26.6% classified as “interme-diate;” and 44.8% as “jumbo.”Exhibit “A” shows the comparativeheights of products stacked onwooden pallets and on slipsheets.Note that in most cases an extra oneor two tiers of cases can be addedwhen slipsheets are used. Since themechanical refrigeration charge bythe railroads is a fixed cost per trip,the refrigeration cost per case canbe reduced. Obviously, wherefreight tariffs provide for a per carfreight charge, the cost savings aredramatic when loading cars to theirfull volume and weight capacities.The important thing with slipsheetusage is that interior loading spaceis not sacrificed at the expense ofthe pallets. Yet, the load can bemechanically loaded and unloadedreducing warehouse labor costs.There is no concern for protrudingnails or damaged pallet parts whichoften cause damage to cases.

SLIPSHEET BENEFITS IN THE FOOD DISTRIBUTION SYSTEM

■ The use of slipsheets in the shipping operation can reduce costsconsiderably considering the expendable nature of the slipsheetand the uncertainty of regaining like-quality pallets in a wood palletexchange program. Also, freight costs for manufacturers can bereduced because of the weight differential, slipsheets weighing fivepounds each and wood pallets 55 lbs. each.

■ In the warehousing operation, slipsheets can be economicallystored inside to eliminate infestation concerns. The storage spacerequired is considerably less than for pallets. Further, use of slip-sheets requires a much lower investment in materials handlingsupplies. This is of particular concern to multi-product manufac-turers or food processors who produce their entire annual outputin a few weeks.

■ Unloading time for the average freight car might be six hours for acrew of three workers, or 18 man hours. With slipsheets, it is pos-sible to unload the car with one man using a push/pull attachmentin two man hours. If pallets were used the shipper would haveexpended $390 for pallets versus $25 for slipsheets, adding toproduct costs.

EXHIBIT A

UNIT STACKING HEIGHTS

8.6" 106.7" 96.7" 114.5" 25.00" 110.00" 100.00" 114.5" 210.00" 110.0" 100.0" 114.5" 16.37" 112.0" 102.0" 114.5" 1

Total Height StackedTwo Units High

CaseHeight

OnPallets

OnSlipsheets

InteriorRR Car Ht.

Extra Tierswhen Using

Sheets

43

Cost Comparisons

EXHIBIT BPALLET/SLIPSHEET/DUAL METHOD

For this analysis we must make the following assumptions. The average units in storage is 10,000 pallet spaces.The mean inventory turnover is three times per year – once every four months. Wooden pallets cost $7.50 each(GMA approved type). Fiberboard slipsheets cost 48.5¢ each. Pallet repair costs $2.50 each. Pallets shipped inan open distribution system loop results in a loss of 15%. Approximately 30% of the pallets returned to theoriginal plant or warehouse requires repair before reuse. Pallets used on an intra-plant basis must be repairedonce every two years. Useful pallet life is expected to be five years.

Wooden Pallets OnlyInitial pallets purchase:

10,000 at $7.50 = $75,000 $75,000

Inventory Turnover: Once every four monthsLoss:

10,000 x 15% = 1,500 x $7.50 = 11,250 x 3 33,750Repair:

8,500 x 30% = 2,500 x $2.50 = 6,375 x 3 19,125

Effective Annual Cost $127,875

Wooden Pallets and SlipsheetsInitial pallets purchase: $75,000Initial slipsheets purchased: 10,000 at 48.5¢ = 4,850

Inventory Turnover: Once every four monthsLoss:

Pallets: (None – retained for internal use only)Slipsheets: $4,850 x 2 = 9.700

Repair:Pallets: 10,000 x $1.25 = 12,500


Fiberboard Slipsheets OnlyInitial slipsheets purchase:

10,000 at 58.5¢ $4,850Loss:

10,000 at 48.5¢ x 2 = 9,700


First Year Cost Comparison:Wooden pallets only $127,875Dual System 102,050Slipsheets only 14,550

Five Years Cost Comparison Year 1 Year 2 Year 3 Year 4 Year 5 TOTAL

Pallets OnlyBeg. Yr. Pur. $ 75,000

Loss 33,750 33,750 33,750 33,750 33,750Repair 19,125 19,125 19,125 19,125 19,125

$127,875 52,875 52,875 52,875 52,875 $339,375

Dual MethodBeg. Yr. Pur. $ 79,850 4,850 4,850 4,850 4,850

Loss 9,700 9,700 9,700 9,700 9,700Repair 12,500 12,500 12,500 12,500 12,500

$102,050 27,050 27,050 27,050 27,050 $210,250

Slipsheets OnlyBeg. Yr. Pur. $ 4,850 4,850 4,850 4,850 4,850

Loss 9,700 9,700 9,700 9,700 9,700$ 14,550 14,550 14,550 14,550 14,550 $72,750

44

Cost Comparisons

The use of slipsheets is more appli-cable to the module concept. Thisconcept is a relatively new idea inmaterials handling and is gainingwider acceptance. It providesgreater flexibility to minimize thelabor cost for handling individualcases. Basic unit modules can bedesigned to fully utilize availablestorage or volume of space avail-able while minimizing labor han-dling costs.

A vertical stack of products on slip-sheets will naturally exert lessweight on the bottom case layersthan will a stack of products onwooden pallets. This of courseresults from the absence of palletweight. Each Grocery ManufacturerAssociation (GMA) size palletweighs approximately 55 pounds. Avertical column consisting of sixunits will provide 275 excesspounds of pressure on the bottomcase layers.

Storage space requirements are con-siderably less for slipsheets than fora commensurate amount of pallets.The differential here is approximate-ly 20 to 1. Therefore, slipsheets canmost effectively be stored indoors.

Now let’s consider some draw-backs when using slipsheets.Obviously, almost all ideas or con-cepts have some shortcomings. Sobe it with the slipsheet concept.First, the use of slipsheetsrequires more operator care andtraining. A slipsheet does not pro-vide the forklift “bumping” sur-face provided by a pallet. As aresult, the lift operator must care-fully position the lift surfaceunder the load and not run intothe load before stopping. To do sowould damage the bottom layer ofcases nearest the lift.

Next, a lift operator must not pushthe lifting forks beyond the loaddepth. This is important whenloading a rail car or truck becauseto do so would damage the unitimmediately in front of the load heis positioning.

A rough or abrupt operator caneasily damage the “lip” surface ofthe slipsheet. There are manyslipsheet designs which have a reinforced lip surface. However,even these are defied by many inexperienced or oblivious operators.

Finally, a special slipsheet attach-ment or Push/Pull lift truck shouldbe used. This equipment is special-ly designed to grip the lip surfaceof the slipsheet to pull the loadonto or push the load from the liftplates or forks. Not all firms havethis type equipment since slipsheetsare not as universally used as pal-lets. The accompanying photosdepict an example of a push/pulllift truck. Most “push/pull” attach-ments sell for approximately$6,000 to $7,000. Nevertheless,there are many makes and modelscompetitively marketed today.

Should a load of liquid contents bedamaged while loading or unload-ing or while in transit, the slipsheetcould become saturated, whichwould reduce the tensile strength ofthe fiberboard. Slipsheets with aspecial laminated treatment areavailable which may reduce oreliminate this concern. However,this has not been a problem in theshipment of frozen juice or bever-age concentrates. Storage in freezerwarehouses or refrigerated rail caror trailer environment has not thusfar to our knowledge reduced theeffectiveness of slipsheets.

Photo shows storage of wooden pallets. Due to firesafety regulations, pallets can be stored tomaximum of 20 units high.

Photo shows hundreds of slipsheets stored on pallet, providing sharpcontrast to wooden pallet storage.

45

Cost Comparisons

For a comparison of costs for threedifferent unit handling methods,please refer to Exhibit “B”. Thesethree methods include: (1) Use ofhardwood pallets only; (2) Dualmethod using wooden pallets andslipsheets. The wooden pallets areused only for intra-plant move-ments and storage. A slipsheet isplaced upon each pallet before themerchandise is palletized. (3)Fiber-board slipsheets only. Basedon certain materials handling expe-riences as stipulated in Exhibit“B”, here are the relative costsamortized over a five year period:

It should be emphasized that if theinventory turnover of a firm is greaterthan once every four months (threetimes per year) the economies favor-ing the use of slipsheets becomeseven more appealing.Here is a comparison of some ofthe overall benefits of each method:

In summary, the use of eithermethod will depend largely uponthe intended application. As a gen-eralization, the prevailing factorsare cost and control. Open distri-bution loop channels favor slip-sheet usage, while closed loop sys-tems favor wooden pallet usage.But, this is a generalization. Manyfactors must be considered by thedecision maker. However, it is mostdifficult to overlook the tremen-dous cost savings which a firm canrealize when using slipsheets.

Reprinted from the May/June1978, issue of GroceryDistribution with the permis-sion of Richard W. Mulville,Editor and Publisher

Wooden Pallets only –$339,375Dual Method –$210,250Slipsheets only –$ 72,750

Capital Cost XLift Operator Training Requirements XCarrier Cube Utilization XMHE Cost Outlay XReusability Feature XInfestation XPallet Repair Cost XExpendability XBetter for Closed Loop Systems XBetter for Open Loop Systems XLiquid Damage Retardation XDamage from Protruding Objects XStorage Requirements Advantage X(Unused Pallets vs Slipsheets)

CONCERNS FAVORSSlipsheets Wooden

Pallets

46

General Foods

WHY GENERAL FOODSCONVERTED TO SLIPSHEETS

After months of intensive researchand testing, General Foods begana conversion process that was toeliminate more than 350,000wood pallets from its distributionsystem through a changeoverwherever feasible to slipsheets.

By C.W. EbelingMethods and FacilitiesDevelopment Manager,

General Foods Corporation

General Foods began the firstmajor unitized shipping program inthe food industry 16 years ago. Itrepresented the culmination of sev-eral years of planning and testingalternative unitized shipping meth-ods. Many different kinds of pal-lets, both returnable and one-waytypes, had been tried during thetesting period along with multi-tineand slipsheet palletless methods.

The 48" x 40" four-way woodenpallet emerged as the preferredunitized shipping method at thetime for several reasons. It was rel-atively low cost. Good hardwoodpallets could be purchased for lessthan $3.00 each and lasted up tothree years of use. Cost per tripwas in the 10¢ to 15¢ range. It wasflexible in that it could be shippedeither in railcar or truck and wascapable of being handled by forklift trucks from all sides and by rel-atively low cost pallet jacks andwalkies from two sides.

Implementation of an industry wideunitized program overwhelminglyfavored the pallet method at the time.Most of fork lift trucks and used pal-lets for storage of products in theirwarehouses. Few, however, had slip-sheet attachments then. Out cus-tomers liked the palletized method.Quick turnaround of equipment onthe docks appealed to them andmany extended the concept all theway to their retail store deliveries.

By 1974, approximately 65% of ourvolume moving between plants andthe field warehouses was palletizedand 75% of the volume shippedfrom the field warehouses to cus-tomer terminals was palletized.Had this volume been shipped non-unitized, annual labor costs to loadand unload piece by piece wouldhave increased over 4 million dol-lars a year and customers costs toreceive General Foods' productsacross their docks, over 2 milliondollars a year.

Despite the fine record of achieve-ment for palletized shipping duringthe early years of the program, thequality of the pallets began to dete-riorate as shipping volumes grewand the pallet exchange poolexpanded to include a large num-ber of other shippers and cus-tomers. It became more and moredifficult to obtain good hardwoodpallets to the original specificationsestablished for the program and itbecame virtually impossible to keepup with pallet repairs.

The problems of pallet quality in anexchange pool became apparent asearly as 1965. In order to reducedependence upon the number of

The obvious space-saving advan-tage of using slipsheets was amajor factor in General Foods'change to slipsheets

At a General Foods plant, a push/pull attachment handles slipsheet loads ofKool-Aid product. The investment required to equip trucks with attachmentsto handle slipsheet loads was offset by General Foods through reduction inpallet costs and benefits from increased storage and shipping space.

47

General Foods

pallets required in the system,General Foods inaugurated a clampprogram that year for the handlingand storage of a large number ofthe products that were clampable.That took a sizable number of pal-lets out of the warehouses but hadno effect on the number requiredfor shipments between plants andwarehouses and customer termi-nals. In subsequent years moreproducts were made clampable byshrink wrapping methods until by1976 about 50% of the throughputvolume was handled by clamps.Although very effective for storage,the use of clamps for shipping islimited. The problem is at theunloading ends since maintenanceof voids around the clampableloads to permit entry of clamp padsis difficult to maintain in transit.That, along with the high cost ofpre-paring loads for clampablehandling, (many loads require filmwrapping) discouraged the idea ofgoing to an all clamp program.

By the end of 1976, the need to dosomething about the problemswith pallets had become moreurgent than ever. The cost of newpallets had doubled as had thecosts of repair. Few pallets lastedeven a year and cost per pallet tripwas in the area of $1.00 each.Industry efforts to control thequality of pallets in the exchangesystem were not proving to be suc-cessful. Problems of sanitationincreased with general deteriora-tion of the pallets in the pool anddamage to products caused bybroken boards and protrudingnails became common.

With the onset of the energy crisisand demand for high utilization oftransportation equipment, carriersrealized that pallets were taking

considerable space and displacingroom for revenue producing pay-load. (See photo comparing stackof 56 pallets, the number in a railcar, vs. a stack of 56 slipsheets.)The free return of pallets in railcars was under questions. Withoutthat privilege the cost per palletwas expected to increase about$1.20 each trip in oder to returnthe pallets.

General Foods then took anotherlook at the prospect for the dispos-able slipsheet. By 1976, severallarge manufacturers had convertedto slipsheets for rail shipments andmost of our customers hadequipped their rail docks with slip-sheet handling equipment.

In the beginning, we had a numberof concerns about the use of slip-sheets. These were:

■ Handling efficiency in relation to pallets—

Pallets, despite their problems area simple handling device. Weexpected some loss of productivityin a conversion to slipsheet han-dling and storage but were not surejust how much.

■ High stacking on slipsheetson warehouse floorsappeared to be especiallydifficult if at all feasible—

It is easy to run forks into a palletand pull off a load 15 feet or morehigh, and it is a simple matter tomove clamp pads around toploads, but the idea of gripping asheet under a top load and pullingit onto an attachment withoutpulling the entire stack over wasexpected to create problems.

■ A survey of our customers indi-cated that although just about all ofthem had slipsheet equipment onrail docks and would participate in

a slipsheet rail program, few feltready to accept deliveries of slip-sheet loads in trailers across theirrail docks. There were different rea-sons for this, probably the mostcommon being that there was nosimple handling equipment theequivalent of pallet walkies toextract slipsheet loads from trailers.

■ A substantial capital investmentwas expected in order to convertautomatic palletizers to slipsheetunitizing and to provide slipsheetattachments for the lift trucks. Insome cases it would be necessary toreplace lift trucks that did not havesufficient counter weight capacityfor installation of a slipsheet attach-ment that weighs nearly a ton andstill carry the required payloads.

The concerns listed abovewere handled as follows:■ In order to establish productivityof slipsheets vs. pallets, we carriedout a long series of test shipmentsand a pilot storage operation. Inthe process, the importance of spe-cial handling techniques and oper-ator training were found to beespecially critical to minimizinghandling penalties. Our field oper-ations people produced a trainingfilm and manual and providedcopies to each field location. Theyconverted one warehouse com-pletely to the palletless methodsand used it as a central slipsheettraining center for super-visorsfrom 34 other warehouse andplant locations.

■ The problem of high stacking theslipsheet loads was solved partly bytraining in the technique, but alsoby improved stabilization of theslipsheet loads. Where justifiable,shrink or stretch film wrapping isby far the most efficient form ofload stabilization.

48

General Foods

The use of palletizing adhesivesproved to be both cost and per-formance effective for a number ofthe products. A liquid type glue isused that loses its tensile strengthafter a couple of days thereby mak-ing cases easy to lift off on receiv-ing ends. It maintains shear resist-ance, however, thereby stabilizingthe loads for ship-ping and for han-dling in high stacks.

■ It was recognized that customersreceiving by trailers, (roughly 50%of our outbound shipments fromfield warehouses) would want tocontinue to receive on pallets forsome time, at least until some sim-ple handling equipment is devel-oped that will extract slipsheetloads as effectively as do handwalkie trucks with pallet loads. Ourimmediate objective became one ofminimizing the number of pallets inthe system and doing all we couldto get a slipsheet low lift truckdeveloped for the future. In themeantime, loads stored on slip-sheets and clamp loads are simplyplaced on to the pallets for out-bound shipments via trailers.

■ The capital investment necessary toconvert plant equipment to unitize onslipsheets and to provide slipsheetattachments and new trucks whereneeded, was justified by the reductionof pallet costs, and the benefits fromhigher density storage and shippingof many of the products.

The conversion to slipsheets wasstarted early in 1977, and is nownearing completion at all locations.The number of pallets being elimi-nated from the system exceededoriginal projections of 350,000. Theaccompanying drawing gives an ideaof how big a pile of wood that manypallets represents. If you place theempty pallets in stacks 50 high each

and the place the stacks end to end,you have a wall of wood 25 feet highand 5.3 miles in length. It amountsto approximately 16,000 tons ofwood that are no longer needed toget our products to market.

To sum it all up, UNITIZED SHIP-PING is essential to cost effectivehandling and shipping in the foodindustry. The wooden pallet, themainstay method of unitized ship-ping over many years that con-tributed so much to economicalhandling and shipping and whichwas such a simple and effectivedevice to use, ran into changingconditions occasioned by growingshipping volumes and the difficul-ties of controlling their quality ofreturnable pallets in a vary largepallet exchange pool.

We at General Foods, feel that dis-posable slipsheets are better suitedto today's needs and conditions,and, despite the concerns and thedifficulties of converting a longstanding unitized system basedupon use of wooden pallets, believethat a substantial part of unitizedshipping volume must be convertedto slipsheets if the food industry isto continue to receive the benefitsof unitized handling in the future.

Reprinted from the May/June1978, issue of GroceryDistribution with the permis-sion of Richard W. Mulville,Editor and Publisher

The illustration showsthe impact of the con-version to slipsheets atGeneral Foods. Morethan 350,000 woodpallets have been elim-inated from the sys-tem. Stacked 50 high,that amount wouldrepresent a wall of pal-lets 25 feet high and5.3 miles long. Thetotal weight wouldcome to 16,000 tons.

IMPACT—ELIMINATIONOF 350,000 PALLETS

EMPTY PALLETS 50HIGH IN STACKS

650 CARLOADS350,000 PALLETS16,000 TONS OF WOOD

49

Work Sheet

PALLET VERSUS SLIPSHEET COSTS COMPARISON

Pallet System – Data Required

1. Number of units shipped ________________2. Cost per pallet ________________3. Number of pallets owned ________________4. Average pallet life ________________5. Cost of money in percent ________________6. Average weight of outbound freight ________________7. Weight of pallets ________________8. Cost of pallet return freight ________________9. Total pallet repair cost annually ________________

10. Time required to store and remove loads from storage ________________11. Time required to stage and load with pallets ________________12. Labor rates ________________13. Time to unload and return pallets, inspect, sort

and administrate ________________

FORMULA (Store & Ship on Pallets)

Cost per pallet x No. of Pallets Owned ÷ Average Pallet Life = Annual Replacement Pallet Expense

______________ x ______________ ÷ ______________ = ______________

Cost per pallet x No. of Pallets Owned x Cost of $ Percent = TOTAL Interest of Expense

______________ x ______________ x ______________ = ______________

Total Pallet repair cost annually = TOTAL Pallet RepairCosts

______________ ______________

No. of Units x Weight of Pallets x Average Cost of = TOTAL Freight Costsshipped Outbound Freight to Ship Pallets

______________ x ______________ x ______________ = ______________

50

Work Sheet

PALLET VERSUS SLIPSHEET COSTS COMPARISONAdditional items not included but should be considered when comparing slipsheets to wood pallet handling:

1. Fire insurance for pallets2. Pallet shortages due to the pallet float3. Space occupied by pallet versus used for product can be up to 10%4. Damage caused by pallets – broken deck boards, over or underhang

of product, nails, etc.5. Sanitation: The FDA is inspecting pallets for rodent leavings with black lights.6. Pallet returns interior to those shipped7. Storage space required for pallets versus slipsheets – 100 slipsheets stored

is the same as 1 pallet8. Potential future shortage of pallets and increasing costs9. Safety

FORMULA (Store & Ship on Pallets) (cont.)

Number of units x Weight of Pallets x Average Cost of In- = TOTAL Freight Costs shipped bound Returned Frght. to Return Pallets

______________ x ______________ x ______________ = ______________

Time to Unload and x Number of Loads x Labor Rates = Pallet Exchange Return Pallets, ExpenseInspect, Sort andAdministrate

______________ x ______________ x ______________ = ______________

Time required to x Number of Loads x Labor Rates = TOTAL Labor CostStore and Remove to Store and RemoveLoad from Storage from Storage

______________ x ______________ x ______________ = ______________

Time required to x Number of Loads x Labor Rates = TOTAL Labor CostStage and Load with to Stay and LoadPallets

______________ x ______________ x ______________ = ______________

TOTAL COST TO SHIP ON PALLETS = ______________

TOTAL COST TO ÷ NUMBER OF LOADS = COST PER LOADSHIP ON PALLETS

______________ ÷ ______________ = ______________

51

Work Sheet


Slipsheet System – Data Required

1. Number of loads ________________2. Cost of slipsheets ________________3. Cost of slipsheet dispenser ________________4. Slipsheet dispenser average life ________________5. Slipsheet dispenser number of units required ________________6. Cost of load push/pull ________________7. Load push/pull average life ________________8. Load push/pull number of units required ________________9. Time to store and remove load

from storage on captive pallet ________________10. Time to stage and load with slipsheets ________________11. Labor rate ________________12. Cost of captive pallet ________________13. Number of captive pallets ________________14. Average life of captive pallets ________________15. Cost of Money ________________16. Pallet repair of captive pallets ________________

52

Work Sheet

FORMULA (Store on Captive Pallets – Ship on Slipsheets)Number of Loads x Cost of Slipsheets = TOTAL SlipsheetShipped Expense

______________ x ______________ = ______________

Cost of Slipsheet x Number of Units ÷ Average Life = Annual CapitalDispenser Required Expense for Slipsheet

Dispenser

______________ x ______________ ÷ ______________ = ______________

Cost of Load x Number of Units ÷ Average Life = Annual CapitalPush/Pull Required Expense for Load

Push/pulls

______________ x ______________ ÷ ______________ = ______________

Time to Store and x Number of Loads x Labor Rate = TOTAL Labor Cost toRemove Load from Store and Remove Storage on Captive Pallet Loads from Storage

______________ x ______________ x ______________ = ______________

Time to Stage and x Number of Loads x Labor Rate = TOTAL Labor Cost toLoad with Slipsheets Store and Remove

from Storage

______________ x ______________ x ______________ = ______________

Cost of Captive x Number of Captive ÷ Average Life of = Annual Captive PalletPallets Pallets Captive Pallets Replacement Cost

______________ x ______________ ÷ ______________ = ______________

Cost of Captive x Number of Captive x Cost of Money = TOTAL InterestPallets Pallets Expense

______________ x ______________ x ______________ = ______________

Pallet Repair of Captive Pallets = TOTAL Repair ofCaptive Pallets

TOTAL COST TO STORE ON CAPTIVE PALLETS & SHIP WITH SLIPSHEETS = ______________

TOTAL COST TO STORE ON CAPTIVE PALLETS ÷ Number of Loads = COST PER LOAD& SHIP WITH SLIPSHEETS______________ ÷ ______________ = ______________

SUMMARY PER LOAD SAVINGS PER LOAD TOTAL SAVINGS

Pallets Only

Captive Pallets & Slipsheets

53

Work Sheet


Optional methods to consider in storing & shippingunitized loads:

1. Store on slipsheet and ship on slipsheets2. Store products that are clampable with carton clamps –

the balance on slipsheets on captive pallets and ship on slipsheets

Because of problems associated with pallets and pallet exchange programs, the foodindustry is accelerating its transition for handling products either on slipsheets orpalletless. The key to a successful program is proper initial planning including:

1. Education of top management2. Training of lift truck drivers3. Proper equipment4. Establishing a test location to develop a successful slipsheet material handling system that

will enable personnel within your company to become familiar with the requirements ofslipsheet handling prior to expanding it to all of your shipping and receiving locations.

54

Work Sheet


Pallet System – Data Required

1. Number of units shipped ________________2. Cost per pallet ________________3. Number of pallets owned ________________4. Average pallet life ________________5. Cost of money in percent ________________6. Average weight of outbound freight ________________7. Weight of pallets ________________8. Cost of pallet return freight ________________9. Total pallet repair cost annually ________________

10. Time required to store and remove loads from storage ________________11. Time required to stage and load with pallets ________________12. Labor rates ________________13. Time to unload and return pallets, inspect, sort,

and administrate ________________

450,000

$8.50

300,000

3 years

12%

40,000 lbs.

292,500

$1.00

$100,000

4 min.

2 min.

$9.00/hr.

.24 min.

55

Work Sheet

FORMULA (Store and Ship on Pallets)Cost per Pallet x Number of Pallets ÷ Average Pallet Life = Average Replacement

Owned Pallet Expense

______________ x ______________ ÷ ______________ = ______________

Cost per Pallet x Number of Pallets x Cost of $ Percent = TOTAL Interest ofOwned Expense

______________ x ______________ x ______________ = ______________

Total Pallet repair cost annually = TOTAL Pallet RepairCosts

______________ = ______________

Number of x Weight of Pallets x Average Cost of = TOTAL Freight Costsunits shipped Outbound Freight to Ship Pallets

______________ x ______________ x ______________ = ______________

Number of x Weight of Pallets x Average Cost of = TOTAL Freight Costsunits shipped Inbound Freight to Return Pallets

______________ x ______________ x ______________ = ______________

Time to Unload and x Number of Loads x Labor Rates = Pallet Exchangereturn Pallets, ExpenseInspect, Sort andAdministrate

______________ x ______________ x ______________ = ______________

Time required to x Number of Loads x Labor Rates = TOTAL Labor CostStore and Remove to Store and RemoveLoad from Storage from Storage

______________ x ______________ x ______________ = ______________

Time required to x Number of Loads x Labor Rates = TOTAL Labor CostStage and Load to Stage and Loadwith Pallets

______________ x ______________ x ______________ = ______________

TOTAL COST TO SHIP ON PALLETS = ______________

TOTAL COST TO SHIP ON PALLETS ÷ Number of Loads = COST PER LOAD

______________ ÷ ______________ = ______________

$8.50 300,000 3 years $850,000

$8.50 300,000 12% $306,000

$100,000 $100,000

450,000 65 lbs. $1.00 cwt $292,000

450,000 65 lbs. $1.00 cwt $292,000

.24 min. 450,000 $.15/min ($9.00/hr.) $16.200

4 min. 450,000 $.15/min ($9.00/hr.) $270,000

2 min. 450,000 $.15/min ($9.00/hr.) $135,000

$2,261,200 450,000 $5.02

56

Work Sheet

PALLET VERSUS SLIPSHEET COSTS COMPARISONAdditional items not included but should be considered when comparing slipsheets to wood pallet handling:

1. Fire insurance for pallets2. Pallet shortages due to the pallet float3. Space occupied by pallet versus used for product can be up to 10%4. Damage caused by pallets – broken deck boards, over or underhang

of product, nails, etc.5. Sanitation: The FDA is inspecting pallets for rodent leavings with black lights.6. Pallet returns interior to those shipped7. Storage space required for pallets versus slipsheets – 100 slipsheets stored

is the same as 1 pallet8. Potential future shortage of pallets and increasing costs9. Safety

57

Work Sheet


Slipsheet System – Data Required1. Number of loads ________________2. Cost of slipsheets ________________3. Cost of slipsheet dispenser ________________4. Slipsheet dispenser average life ________________5. Slipsheet dispenser number of units required ________________6. Cost of load push/pull ________________7. Load push/pull average life ________________8. Load push/pull number of units required ________________9. Time to store and remove load

from storage on captive pallet ________________10. Time to stage and load with slipsheets ________________11. Labor rate ________________12. Cost of captive pallet ________________13. Number of captive pallets ________________14. Average life of captive pallets ________________15. Cost of Money ________________16. Pallet repair of captive pallets ________________

450,000$.70

$30,00010 years

5$7.0005 years

10

4 min.4 min.

$.15/min. ($9.00/hr.)$20

50,0005 years

12%$120,000

58

Work Sheet

FORMULA (Store on Captive Pallets – Ship on Slipsheets)Number of Loads x Cost of Slipsheets = TOTAL SlipsheetShipped Expense

______________ x ______________ = ______________

Cost of Slipsheet x Number of Units ÷ Average Life = Annual CapitalDispenser Required Expense for Slipsheet

Dispenser

______________ x ______________ ÷ ______________ = ______________

Cost of Load x Number of Units ÷ Average Life = Annual CapitalPush/Pull Required Expense for Load

Push/pulls

______________ x ______________ ÷ ______________ = ______________

Time to Store and x Number of Loads x Labor Rate = TOTAL Labor Cost toRemove Load from Store and Remove Storage on Captive Pallet Loads from Storage

______________ x ______________ x ______________ = ______________

Time to Stage and x Number of Loads x Labor Rate = TOTAL Labor Cost toLoad with Slipsheets Store and Remove

from Storage

______________ x ______________ x ______________ = ______________

Cost of Captive x Number of Captive ÷ Average Life of = Annual Captive PalletPallets Pallets Captive Pallets Replacement Cost

______________ x ______________ ÷ ______________ = ______________

Cost of Captive x Number of Captive x Cost of Money = TOTAL InterestPallets Pallets Expense

______________ x ______________ x ______________ = ______________

Pallet Repair of Captive Pallets = TOTAL Repair ofCaptive Pallets

TOTAL COST TO STORE ON CAPTIVE PALLETS & SHIP WITH SLIPSHEETS = ______________

TOTAL COST TO STORE ON CAPTIVE PALLETS ÷ Number of Loads = COST PER LOAD& SHIP WITH SLIPSHEETS______________ ÷ ______________ = ______________

SUMMARY PER LOAD SAVINGS PER LOAD TOTAL SAVINGS

Pallets Only

Captive Pallets & Slipsheets

450,000 $.70 $315,000

$30,000 5 10 years $15,000

$7,000 10 5 years $14,000

4 min. 450,000 $.15/min. ($9.00/hr.) $270,000

4 min. 450,000 $.15/min. ($9.00/hr.) $270,000

$20 50,000 5 years $200,000

$20 50,000 12% $120,000

$1,204,000

$1,204,000 450,000 $2.67

$5.03 Base $.00 Base $.00

$2.67 $2.36 $1,062,000

59

Work Sheet


Optional methods to consider in storing & shippingunitized loads:

1. Store on slipsheet and ship on slipsheets2. Store products that are clampable with carton clamps –

the balance on slipsheets on captive pallets and ship on slipsheets

Because of problems associated with pallets and pallet exchange programs, the foodindustry is accelerating its transition for handling products either on slipsheets orpalletless. The key to a successful program is proper initial planning including:

1. Education of top management2. Training of lift truck drivers3. Proper equipment4. Establishing a test location to develop a successful slipsheet material handling system that

will enable personnel within your company to become familiar with the requirements ofslipsheet handling prior to expanding it to all of your shipping and receiving locations.

60

Slipsheets vs. Pallets

SLIPSHEETS VS. PALLETS:THE DECISION MAKINGPROCESS

There are many considerations,and considerable analysis that hasto be performed, prior to a deter-mination by a company, as towhether or not slipsheets shouldreplace long standing pallet pro-grams, eitherpartially or totally.

There are comparisons and evalua-tions that must precipitate anymajor conversion of this nature.What is helping stimulate this think-ing process is the abnormally highcost of pallets.

While it is true that slipsheets donot have the rigidity of a woodenpallet, there are other considera-tions that must be examined in thepotential developmental process.The internal combustion engineand the airplane were not boomingsuccesses the first time out. Proper,sound economic reasoning mustprevail, in order to determine notonly the financial soundness of aprogram of this magnitude, but allthe ramifications that are contin-gent to a program of this scope.

Savings are not the sole purpose,although they bear a considerablereason to go into a slipsheet pro-gram. I have broken down thiscomparison into two categories:I. GENERAL COMPARISONS:Pallets vs. Slipsheets, andII: COST COMPARISONS:Pallets vs. Slipsheets.

I. General Comparisons: Pallet vs. Slipsheets1. Costs:

Wooden pallets range in cost from $4.00 to $13.00depending upon availability of woods and geographicalnature of use. Slipsheets range from 37¢ to 50¢; and aplastic slipsheets from $1.75 to $2.50 each.

2. Maintenance Costs:Wooden pallets cost anywhere from $2.20 per year forplywood (estimated 7 year life) to $2.74 per year forboard (estimated 4 year life). Currently most compa-nies lost pallets with regularity and for other reasons,which will be covered in another section of this paper.

3. Storage:Taking into account the value of storage space, for everypallet stored, 50 to 100 slipsheets (depending uponthickness-caliper) can be stored in the same space.

4. Space Savings:As shown in the comparison, 10% additional storagespace can be gained.

5. Freight Costs:Wood pallets weigh approximately 65 pounds. Assuminga 40 unit load of low cube pallets were shipped.

This would mean that 2,600 pounds of pallets have to be paid for infreight. If the cost per hundred weight were $1.00, the freight cost doesnot include the pallets is $26.00. This freight cost does not include thepallet back haul expense. Slipsheets weigh about 3 pounds a piece;translated to the same freight rate that would be 120 pounds at $1.00per hundred weight, only making it $1.20 extra per the slipsheets.

6. Payload:It is feasible to measure your payload space 10% onrail cars, trucks, and on containers.

7. Safety:Wood pallets weighing about 65 pounds can cause backinjury, splinters, foot injury, and completely recyclable,and offer the characteristics of being a salable item.

8. Disposal:Wood pallets are not recyclable, but are repairable.Slipsheets are completely recyclable and offer thecharacteristic of being a salable item.

9. Damage to product:In the handling and storage of products, damage must beconsidered. Wooden pallets cause damage. Loose nailsand splinters gouge and tear cartons. Loads can settle

61


Once this basic data has beencollected, the final analysis begins.These are specific formulas thatcollected data is then put throughas you can see by visual material.The economic justification of a pro-gram of this scope is no differentthan any other economic justifica-tion that you go through, albeit,machinery, lift trucks, etc.

How the program is presented tomanagement is also an importantfactor. No matter how good thenumbers may be, programs stillhave to be sold. Only you can bethe judge of that.

9. Damage to product cont.:and become deformed through overhang and broken ormission deckboards. Second tier pallets can partiallycrunch lower pallets of product. Slipsheets do not causedamage if properly handled. Slipsheets offer still anotheradvantage.

10. Return Program:The elimination reduction of wooden pallets greatlyreduces the cost in pallet return programs.

These costs include:■ Pallets returned are inferior to those shipped■ Return shipping costs■ Storage space for consolidated shipments■ Bookkeeping of pallet exchange■ Lost pallets■ Storing of pallets

Other considerations in the conversion to slipsheet handling shouldinclude:

■ Fire insurance cost for pallets■ Sanitation – infestation of pallets

What must also be considered is the economics of converting into aprogram of this magnitude.

II. General Comparisons: Pallet vs. SlipsheetsIn the course of performing this analysis, there is both pallet system –data and slipsheet system – data required.

Pallet system – data required

1. Number of units shipped2. Cost per pallet3. Number of pallets owned4. Average pallet life5. Cost of money in percent6. Average weight of outbound freight7. Weight of pallets8. Cost of pallet return freight9. Total pallet repair cost annually

10. Time required to store and remove loads from storage11. Time required to stage and load with pallets12. Labor rates13. Time to unload and return pallets, inspect, sort,

and administrate

62

REQUIREMENT FORDEVELOPING A SUCCESSFULSLIPSHEET PROGRAM(Palletless Handling System)

1. Top management approval2. Sales and marketing impact3. Customer education4. Traffic involvement5. Distribution engineering &

development6. Manufacturing planning7. Hourly personnel training8. Implementation9. Follow-up

10. Audit savings

I. TOP MANAGEMENT APPROVAL

1. Explanation:Slipsheets vs. pallets

2. Economics & advantages3. Impact this will have on

business units4. Industry trends in the 1980's5. Progress & Communications

on program

II. SALES & MARKETING IMPACT

1. Advantages to company2. Advantages to customer3. Advantages to carrier4. Solicit assistance in selling

program to customers5. Industry trends in 1980's

III. CUSTOMER EDUCATION – DATA BASE

1. Impact on customersoperations

1.1 Material handling equip-ment

1.2 Product handling1.3 Slipsheet capacity1.4 Storage & staging1.5 Order selection1.6 Dock configuration1.7 Work rules for carrier

drop off2. Advantages of slipsheet

program3. Pallet problems

IV. TRAFFIC INVOLVEMENT

1. Customer coordination2. Carrier responsibility3. Product liability3.1 In house carrier3.2 Outside carrier4. Slipsheet program

indoctrination5. Rate analysis & revision

V. DISTRIBUTION ENGINEERING & DEVELOPMENT

1. Slipsheet indoctrination1.1 Customers1.2 Carriers1.3 Management & other

company personnel2. Material handling equipment

testing3. Slipsheet testing4. Stretch wrap machinery and

film testing5. Customer analysis – physical

facilities & equipment6. Distribution center analysis7. Systems planning8. Pallet tiering & carton analysis

(compac) (manufacturing)9. Justification and cost savings

analysis10. Equipment purchase or lease11. Personnel training12. Program implementation13. Program follow-up14. Savings audit

VI. MANUFACTURING PLANNING

1. Revise automatic palletizingequipment

2. Revise pallet tiering heights3. Adapt material handling

equipment


II. General Comparisons:Pallet vs. Slipsheets cont.

Slipsheet system – data required

1. Number of loads2. Cost of slipsheets3. Cost of slipsheet dispenser4. Slipsheet dispenser average life5. Slipsheet dispenser number of units required6. Cost of load push/pull7. Load push/pull average life8. Load Push/pull number of units required9. Time to store and remove load from storage on captive pallet

10. Time to stage and load with slipsheets11. Labor rates12. Cost of captive pallet13. Number of captive pallets14. Average life of captive pallets15. Cost of money16. Pallet repair of captive pallets

63


HANDLING METHOD—SHIPPING MODE

INTERNATIONAL SHIPMENTS

■ plant to warehouse■ warehouse to warehouse

PALLET SLIPSHEET DEADPILED

RAIL40% 55% 5%

TRUCK90% 10%

PALLET SLIPSHEET DEADPILED

RAIL25% 70% 5%

TRUCK60% 5% 35%

PERCENT OF CASE SHIPMENTS

Rail 16%Common carrier 50%Contract carrier 9%Company fleet 17%Backhaul 8%

TOTAL 100%

Pallet 38%Slipsheet 22%Deadpile 40%

TOTAL 100%

OUTBOUND SHIPMENTS:

■ plant to customer■ warehouse to customer

SLIPSHEET COST ANALYSIS

INITIAL PURCHASE COST (EACH)

Annual usage/costCost per pallet x number pallets owned + avg. lift8.00 x 10,000 + 2 years =

Repair costs (avg. 25% of orig. cost)(25% x 8.00 x 10,000)

Storage

Warehouse cube loss

Special handling equipmentPallet forks: 400 + 5 yr. lifePush/Pull: 10,000 + 5 yr. life

Administration expenses(ordering, recordkeeping, pallet expediting, claims and returns)

Tare weight freight cost($1.50 cwt) Pallets at 50 lbs.$1.50 cwt x 50# x 30,000 slipsheets at 3 lbs

Pallet return freight cost

Transportation cube loss

Empty pallet handling (receiving, storing, sorting, retrieval)

Labor costs (loading, warehousing, unloading, staging)

TOTAL ANNUAL COST

Total unit loads shipped annually

Cost per unit load

*Additional costs to be considered

PALLETS

$ 8.00

40,000

20,000

*

*

80

*

22,500

*

*

*

*

$ 82,580

$ 30,000

$ 2.75

SLIPSHEETS

$ .80

24,000

-0-

Insig.

Insig.

2,000

Insig.

1,350

-0-

Insig.

Insig.

Insig.

$ 27,350

$ 30,000

$ .91

64


SLIPSHEET COST ANALYSIS

INITIAL PURCHASE COST (EACH)

Annual usage/costCost per pallet x number pallets owned + avg. lift8.00 x 10,000 + 2 years =

Repair costs (avg. 25% of orig. cost)(25% x 8.00 x 10,000)

Storage

Warehouse cube loss

Special handling equipmentPallet forks: 400 + 5 yr. lifePush/Pull: 10,000 + 5 yr. life

Administration expenses(ordering, recordkeeping, pallet expediting, claims and returns)

Tare weight freight cost($1.50 cwt) Pallets at 50 lbs.slipsheets at 3 lbs

Pallet return freight cost

Transportation cube loss

Empty pallet handling (receiving, storing, sorting, retrieval)

Labor costs (loading, warehousing, unloading, staging)

TOTAL ANNUAL COST

Total unit loads shipped annually

Cost per unit load

Additional cost notes:

PALLETS SLIPSHEETS

65

Case Histories & Industry Utilization

SLIPSHEETINGTHE WORLD—APPLE COMPUTERS

OBJECTIVES

1. Reduce loading andunloading labor.

2. Eliminate expensive woodenpallet costs.

3. Reduce transportation cost bybetter utilization of theTransporting EquipmentSpec. (trailer/container).

ANNUAL VOLUME OFUNIT LOADS

Annual unit load volume of over 160,000.

TOTAL INVESTMENT

Equipment and start-up slipsheetcost of $200,000.

REQUIREMENTS FOR SUCCESS

1. High quality slipsheet.2. High quality push/pull

attachments.3. Design of specifications for

quality of unit loads.4. Extensive operator training

program.5. Identification of the

Implementation and SupportTeam.

6. Dedicated team for stronginternal and externalcommunications.

RESULTS

1. 78% reduction in pallet cost.Annual savings in excess of $500,000.

2. 75% reduction in unloadinglabor. Annual savings inexcess of $500,000.

3. 20% reduction in transporta-tion costs. Annual savings inexcess of $1,000,000.

Total annual savings forecasted tobe in excess of $2.5 million in thefirst year of full implementation.

IMPLEMENTATIONProgress up to date:

■ 85% of unit loads handled onslipsheets in one year fromthe start of program.

■ Additional 5% will be imple-mented by August 88.

■ 10% of unit loads will be lessthan container/trailer loadsand will continue to beshipped on wooden pallets.

HIGHLIGHTS OF THE PROGRAM

■ Apple is the first ElectronicsCorporation to implementthis material handlingmethod worldwide.

■ The flow of slipsheeted unitloads start fromManufacturing to Distributionand end at freight carriers.

■ Apple has the capability ofshipping and receivingslipsheeted loads worldwide (except 3 European locations—implementation targetedfor July 88).

■ Establishment of a high quali-ty Slipsheet Standard for Electronics Industry.

■ Use of Cascade push/pullequipment worldwide.

Apple Slipsheet ProgramOverview – May 19, 1988


66

Apple & Cascade

CASCADE PLAYS KEYROLE IN WORLDWIDEDISTRIBUTION PROGRAMFOR APPLE COMPUTER

More often than managers real-ize, the existence of an effectivemajor account program isabsolutely essential to obtainingmajor new business. The storybelow tells how the marketingstaff of Cascade Corporation wasable to participate in the AppleComputer distribution team thatrevolutionized the way Applehandles and ships its products.Moreover, Apple’s success in theswitch from wooden pallets tounit loads on slipsheets hasimplications for the entire elec-tronics industry. It’s a classiccase history of national accountmarketing in action.

“We change the way peoplethink,” says Dale Spenner, managerof distribution engineering forApple Computer at Apple’s head-quarters in Cupertino, California.“We’ve changed the way peoplethink about personal computers.Now we have a chance to changethe way the electronics industrythinks about materials handling inshipments from suppliers and tocustomers. It’s an important devel-opment we can all benefit from.

Dale Spenner is talking about an18-month program at Apple forchanging its entire supply train tounit- loads on slipsheets, whicheliminate the cost of wooden palletsand make better use of availablespace in trucks, railcars, and ships.The company has already passed itsinitial goal of 90 percent utilizationof slipsheeting throughout theApple system and believes it will

reach 95 percent compliance fromsuppliers. What’s more, the slip-sheet concept is expanding beyonddelivery of finished componentsfrom OEM suppliers to incomingpiece goods and to Apple’s ownshipments to computer buyers.Sony Corporation, which manufac-turers monitors for Apple, is inves-tigating slipsheeting for its distribu-tion network. It seems that thefolks at Cascade who played a keyrole in Apple’s program may havetouched off a small revolution inthe electronics business.

Benefits. What are the benefits ofslipsheeting, exactly? Well, in aword, they’re impressive. Applesaved $2.5 million in distributioncosts during the first year of fullimplementation on an investmentof $200,000 in equipment andstartup costs. In figuring theseamounts, Dale Spenner says hemade “the costs high and the sav-ings low to get a very conservativemeasure of benefits.

Apple’s savings come mainly fromthe elimination of wooden pallets,which accrue repair and disposalexpenses in addition to their ini-tial cost, and better use of transitvehicle space. With slipsheet han-dling, the pallet is replaced by acorrugated, solid fiber, or plasticsheet. A “load push/pull” attachedto the front of a fork lift grips theedge of the sheet and pulls theload onto the truck’s platens,which serve as the load base during transport.

“Savings involve cost avoidancebecause you don’t have to handleproduct on a piece by piece basis,”Spenner points out. “We don’t everexpect to go back to pallets sothese savings are permanent.”

SPOC. Spenner says that anotherfactor in the success of slipsheetingis a new Apple unitload systemcalled SPOC: Shipping, Planning,Operations Control. Instead of pick-ing a series of individual compo-nents to fill an order–1 monitor, 1CPU, 1 printer–Apple’s system willcall for, say, 15 unit loads of print-ers, 30 of CPUs and 30 of monitors.The SPOC system then providesshipping labels with instructions forsorting the unit loads correctly tofill individual orders.

But who does the sorting? For that,Apple sought assistance from truck-ers. “We negotiated with the freightforwarders to have them breakdown and sort the unit loads intheir ware-houses, “Spennerexplains. “The forward thinkingcarriers realized it would be totheir advantage to know how tohandle slipsheeting when workingwith other customers. Those carri-ers that cooperated with our pro-gram are getting additional busi-ness from other companies that use slipsheeting.”

Simple, but. . . Apple’s programmay sound simple, and it is–untilyou consider what’s involved inmodifying a worldwide distributionsystem from pallets to slipsheets; asystem stretching from Singapore toEurope to Silicon Valley, USA.Here’s where Cascade’s majoraccount program proved to beessential. Cascade’s David Spencertells the story.

“Apple had looked at slipsheetingin 1984 and decided it was the wayto go, though the company wasn’tready for implementation. Then in1987 Apple decided to make thechange. Its distribution peoplebelieved it was a prerequisite towork with a supplier that could be

67

Apple & Cascade

a member of the Apple team duringimplementation. And Cascade hadthe right kind of organization.

“There were at least 10 of our peo-ple heavily involved, “Spencer con-tinues. “Myself, Andy Anderson,Mark Sonda in Japan and his salesmanager, our European representa-tive, and the local Cascade personat each of the locations where slip-sheeting was implemented.

“Initially Apple suppliers looked atslipsheeting with skepticism. Theyasked, “if it’s such a good idea, whyhasn’t it been done before?’ A num-ber of objections had to be over-come. It was only through educa-tion, patience, and a lot of enthusi-asm that Apple succeeded.”

Dale Spenner offers his view ofCascade’s contribution: “Cascadewas like one of our partners.Obviously Cascade has an interestin making it work, but many timestheir people went the extra mile forus–making presentations, makingcontacts for us, talking with folks inorder to get the program onboard.”

Evangelize. Spenner told theNAMA Journal that as a pioneer inslipsheeting in the electronicsindustry Apple wants to “evangelizethe industry.” Early in 1989, proba-bly in February, Apple will hold anopen symposium for the computerindustry to share its experiencewith slipsheeting.

But why give a leg up to the compe-tition? In Dale Spenner’s words,“we want to do this because themissing link in slipsheeting is howour customers receive goods; so itis to our advantage to promote slip-sheeting; as more electronics com-panies use it, more customers willaccept deliveries on slipsheets.”

Executive of the year. For theNational Account MarketingAssociation, Cascade’s ability tosuccessfully assist Apple in a globaldistribution program has extrameaning: Robert C. Warren chair-man of Cascade Corporation, wasselected in 1988 as NAMAMarketing Executive of the Year.

In his acceptance speech Mr.Warren underscored the problemsof selling auxiliary products toindependent lift truck dealers.“Without an intensive and ongoingmajor account activity, the onlyinfluence we would have with themwould be the normal factory ofdesign, price, delivery, parts andservice. The final ingredient neededto assure real success was to createend-user demand. We have highlyqualified representatives who workclosely and continuously with anever expanding group of compa-nies and industries”

And that's what national accountmarketing is all about.

A NAMA case studyCASCADE/APPLE

68

Apple & Slipsheets

SLIPSHEETS GENERATEHYPER-SAVINGS ATAPPLE COMPUTERPatricia Lyons & Dale SpennerApple Computer, Inc.20525 Mariani Ave.Cupertino, CA 95014

ABSTRACT

Over the last 20 years, the foodindustry has shifted increasingproportions of unit loads fromwooden pallets to slipsheets– andenjoyed correspondingly increasingcost savings. Other industries, how-ever, have been slow to embracethis technology. Apple Computerhas pioneered the use of slipsheetsin the electronics industry.

The authors recap the advantagesof slipsheets over wooden palletsand describe the specific cost sav-ings achieved at Apple in the firstyear after conversion. Critical suc-cess factors are identified alongwith a checklist for those consider-ing the use of slipsheets.

INTRODUCTION

In 1987, Apple Computer imple-mented an innovative slipsheetingprogram that has saved over $2.5million in its first year. The objectof this paper is to communicate thepotential competitive advantageslipsheeting offers the electronicsindustry, and the competitive edgeit has already given Apple.

Industrial engineers have long real-ized the advantages of handlingproducts in unit loads, i.e. materialhandling units made up of numer-ous individual items or cases thatare moved and stored as a unit.[1]

There are two objectives in optimiz-ing unitization. One is putting uni-form boxes together and the other

is keeping them together.[2] Theability to both receive and ship byunit loads was critical in the suc-cess of slipsheeting at Apple. Whileuniform boxes can be assembledupon receipt into unit loads onslipsheets, the best place to do thisis at the point of origin–factoriesand Original EquipmentManufacturers (OEMs). At thesame time slipsheeting was beingintroduced to Apple’s vendors andfactories, their warehouses had justimplemented a unitizing system forshipping called Shipment Planningand Operating Control (SPOC)which also proved significant inApple’s success with the slipsheet-ing program.

BACKGROUND

Slipsheets are thin (0.35 to .15inches)[3] fiberboard, corrugatedboard, or plastic sheets that areused instead of pallets to handleunit loads of product. When a unitload is held together by strappingor stretch-wrapping, the slipsheetprovides a stable load base withoutthe bulk, weight, or cost of a con-ventional pallet. The sheets havetabs at two adjacent edges. A fork-lift attachment, called a push/pull,grasps a tab and pulls the unit loadonto two thin highly-polished steelplates called platens. The load isreleased by lowering it to theground and pushing the load offthe platens. The push/ pull attach-ment can be used for handling pal-lets as well as slipsheets.

Slipsheets have been used success-fully in other industries for manyyears. Adolph Coors was one of thefirst companies to adopt a slipsheethandling system. Coors began theirslipsheet program in 1970 afterdiscovering the potential savings in

maximizing the utilized cube spacein railroad cars. Early attemptsended in disappointment when slip-sheets deteriorated in refrigeratedcars during transport. However, areview of the program’s merits con-vinced them that it was a worth-while project to pursue. Plasticslipsheets proved to be the optimalsolution. Coors manufactured theirown plastic slipsheets at a cost of$.60 each. The pallets they usedcost between $8 and $10 each.[3]

BENEFITS

The major benefits of slipsheetingare threefold: savings on freight,savings on labor, and savings onpallet cost. Of the three, the freightsavings is the most significant atApple. A 20% reduction in freightcost translated to over $1,000,000in annual savings. An unloadinglabor reduction of 75% saved Appleover $500,000. A 78% reduction inpallet costs again saved Apple over$500,000. Total savings for Applein the first year have been over $2million, and we project savings infiscal 1989 of over $3 million.These figures do not include addi-tional savings experienced byApple’s vendors.

Apple realized freight savings byloading containers and trailersmore efficiently. Space was savedwhen slipsheets replaced pallets.Because they could put more prod-uct in trailers, they needed fewertrailer loads per year – at least 250fewer in 1988. In addition, theyplanned the use of the space better.They optimized cube utilization ofsea containers by “configuring” theunit load in terms of unit loaddimensions, carton position, andcontainer pattern. In some casesthey even redesigned the packaging

69

Apple & Slipsheets

that didn’t conform well to contain-er and trailer dimensions. Laborsavings were realized in un-loadingocean freight containers. Someoverseas OEM vendors were floorloading containers by hand, whichmeant hand unloading on Apple’sdocks. It took approximately 6worker hours to unload a handloaded ocean container. The use ofslipsheets has reduced the time toless than 30 minutes– a twelvefoldincrease in productivity.

Pallets are expensive. The averagepallet at Apple costs $5.50. Theaverage slipsheet is only $1.10. Inthe Far East the savings are evenmore dramatic. There cots rangefrom $15 to $28 per pallet.Conservation is another issue withthe use of pallets. In 1979 palletsused 50% of the hardwood and15% of all wood produced in theUnited States,[4] Slipsheeting couldsignificantly reduce the use of thisnatural resource.

Some other benefits of slipsheetinginclude improved utilization ofwarehouse dock doors, fasterthroughput, and improved ware-house space utilization. Space issaved because product can bestacked more efficiently, and palletstorage can be reduced. About 100slipsheets can be stored in thespace of one pallet.

SLIPSHEETING THEAPPLE WORLD

Like Coors, Apple also encountereddifficulties in its first attempt atusing slipsheets six years ago. Thefirst sheets tore when grasped bythe push/pull attachment, and theprogram was not promoted wellenough to gain the support neededto succeed.

In February of 1987 the DistributionEngineering Department at Applemet to brainstorm solutions toreceiving problems. Apple wasincurring unacceptable expensesand processing delays in manuallyun-loading ocean containers fromFar East suppliers. The team agreedthat the use of unit loads was thesolution to the unloading problem,and that slipsheets, rather than pal-lets, made sense as the unit loadtechnique. Although Apple hadalready tried the concept, theythought that it would work if fourissues were addressed:

1. Apple needed a slipsheetdesign that would withstandthe tearing problem encoun-tered in their previous tests.This was accomplishedthrough close work withleading slipsheet vendors.

2. An education program wasrequired to get buy-in fromApple management.

3. Material handlers needed tobe trained on the use of thepush/pull attachment prior toany implementation of slip-sheeting. Distribution engi-neering in partnership withtheir equipment vendor pro-vided that training. This timethe training program wasextended to all the AppleDistribution Support Centers.

4. The slipsheeting programwould take a globalapproach, embracing a totalmaterial handling solutionthat included suppliers,freight carriers, and cus-tomers. The Apple team spiritthat rises above departmentalboundaries was essential inmaking this happen.

The ultimate solution transcendedthe local container unloadingproblems and has revolutionizedmaterial handling at Apple.

VENDOR PARTNERSHIPS

A key element in the success of theprogram was starting at vendorsand manufacturing plants. Applewas the first electronics company toreceive product, components andsub-assemblies on slipsheets fromthe Far East. Close work with theapple OEM Purchasing Group wasinstrumental in achieving this pro-gram milestone. Purchasing con-tacted, coordinated, and negotiatedwith suppliers on slipsheetingimplementation issues.

Industrial Engineers from theDistribution EngineeringDepartment visited Apple’s OEMvendors and Apple manufacturingsites. They discussed the cost sav-ings, training and special equipmentinvolved in beginning to ship onslipsheets. They assisted by prepar-ing specific cost and savings data byproduct, supplying the initial slip-sheets, and arranging the rental ofpush/pull attachments until pur-chased attachments arrived.

At first, Far East vendors expressedreluctance to change the way theydid business with Apple. Althoughthese firms excelled in cost effectivemanufacturing, little attentionseemed to be given to making thedistribution of those products moreefficient. It took several trips to theFar East and a great deal of supportto get suppliers started. Now thatthey are realizing the cost benefits(pallets cost as much as $28 a piecein the Far East) some suppliers havebecome slipsheet disciples who arestarting their own programs toswitch their distribution to slipsheets.

70

Apple & Slipsheets

SPOCOnce a growing program wasunder-way to maximize the propor-tion of product arriving in unitloads on slipsheets, Apple neededto keep these unit loads intact aslong as possible. SPOC (ShippingPlanning and Operation Control),Apple’s computer-aided warehousemanagement system, was already inplace to assist in unitization. Underthe previous system, order pickingwas driven by individual customerorder. SPOC replaced this with“wave picking”, a system of pullingproduct by unit loads.[5] SPOC thenallocates these unit loads to cus-tomers and generates unit labelsfor shipment. Since not all ordersare unit loads, the system can alsogenerate labels for individual boxescomposing the unit load. Theessential idea behind SPOC is toeliminate the need to breakdownthe unit load into individual cartonsat the warehouse. A forwarderaccepts the unit load with its indi-vidual labels to different customers.The forwarder takes responsibilityfor breaking down the unit loadafter it leaves Apple. This systemmeans that Apple seldom handlessingle cartons throughout its entiredistribution channel. Developing aclose partnership with their for-warders was instrumental in mak-ing SPOC work.

CHALLENGES

Now 94% of Apple’s products arriveat their distribution centers on slip-sheets. Apple Manufacturing is alsoreceiving slipsheeted unit loads ofsub-assemblies and components. AllUnited States warehouses were receiv-ing unit loads on slipsheets by March1988, and European warehouses willbe receiving by January 1989.

Apple does have some customerswho receive product in unit loadquantities, but who are equippedonly for palletized loads. Thus, thenext challenge is to develop a win-win partnership with those Applecustomers who can benefit fromreceiving on slipsheets.

In addition, Apple is working withslipsheet vendors to develop aneven better slipsheet. Occasionallya tab still tears or is crushed.Apple wants a slipsheet with anabsolutely tear-proof tab. A superi-or slipsheet will be a key factor inthe accelerated implementation byother electronic manufacturers ofthe slipsheet concept over the nextfew years.

IMPLEMENTING ASLIPSHEET PROGRAM

Based upon their experience,Apple recommends the followingissues be addressed for successfulimplementation of a slipsheetingprogram:

1. Top managementcommitment– althoughslipsheet economics areoften the most powerfularguments, industry trendsand effects on other pro-grams must also beaddressed. Once a go-aheadis received, it is also impor-tant to report regularly on progress.

2. Sales and Marketingimpact– these departmentsare interested in anythingthat affects relationshipswith customers. They needto see the advantages to cus-tomers, as well as to thecompany, so they can con-tribute to a strongly support-ive environment.

3. Education of all peopleimpacted by the change(vendors, manufacturing,carriers, customers,etc.)– especially as thechanges impact materialhandling equipment andtechniques. Be certain thatthese people have someoneto whom they can commu-nicate problems as they are encountered.

4. TransportationDepartment involvement–your company’s transporta-tion or traffic departmentcan be especially valuablein assessing the impact oncarrier relations, liabilityissues, rate analysis, andload limitations.

5. Industrial Engineeringleadership– DistributionEngineering was the catalystwithin Apple, and as suchwas involved in every facet ofthe slipsheet program.

6. Manufacturing planning–in addition to material pro-cessing and handling equip-ment, stacking heights mayneed modification.

7. Implementation– should bestaged with clear milestonesand measurement criteria.

8. Follow-up at each stage–minor glitches which hardlyaffect existing systems can eas-ily undermine new programs.

9. Audit savings– especiallywhere major savings areexpected, early reporting of interim results can helpkeep pioneers motivatedwhen faced with inevitableproblems.

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Apple & Slipsheets

10. Team spirit– The size ofthe slipsheeting team willgrow with the project. Teamwork is essential to the suc-cessful implementation ofthe program, so it is impor-tant to keep communicationopen and flowing betweenteam members.

CONCLUSION

The success of the SlipsheetingProgram hinged on many factors.

■ Global strategy was a basicgoal requirement.

■ Implementation extendedfrom vendors to Apple’s dis-tribution centers to their out-bound carriers.

■ Slipsheeting is a simpleprocess, however it requiresextensive communication,support, training, follow-up,and patience.

However, the essential element thatmade it possible was the commit-ment and dedication of each per-son involved in the effort. TheSlipsheeting Team included peopleinside and outside of Apple work-ing to do what’s best for Apple andwhat’s best for the industry.

To quote one of Apple’s DistributionEngineers, “The slipsheet unit loadconcept will save any company inmaterial costs, transportationexpenses, and handling labor. Theoverall savings will only vary by com-pany depending on their receivingand shipping volumes.”

[1] Tompkins, J.A. andSmith, J.D., Editors.The Warehouse Management Handbook, McGraw-Hill Book Company,(1988)

[2] Balough, Mike,Unitization,Lantech, Inc., (1984)

[3] Ackerman, K.A., PracticalHandbook ofWarehousing,The Traffic Service Corp.(1986)

[4]Spencer, D.,Put It On A Slipsheet!,Paper Board Packaging, (October 1979)

[5]Yocam, Delbert W.,Technology TakesBite of Success,Transportation & Distribution, (Presidential Issue 1988-1989)

AcknowledgementsDale Spenner, Manager of the Distribution Engineering Department atApple, and Patricia Lyons, Distribution Engineering Project Coordinatorcompiled this paper from material gathered from the real authors-allthose people inside and outside of Apple who generously recappedtheir experiences in implementing slipsheeting at Apple, and who sup-plied articles and documents for background research.

Thank you Cascade Corporation, manufacturer of forklift truck attach-ments, for supplying so many fine articles on slipsheeting and materialhandling, and for outstanding support of the Slipsheet Program.

Thank you to all the Apple suppliers and customers who ship andreceive on slipsheets. Thank you to all those in apple’s DistributionSupport Centers, Warehouse Operations, Manufacturing, DistributionSupport OPerations, Distribution Engineering, Pacific Logistics,Transportation, and OEM Purchasing, who have worked so hard tomake the Slipsheet Program a success.

72

Home Depot

“YOU MUST USE SLIP-SHEETS.”– HOME DEPOTHome Depot’s suppliers got theletter of the law. Now they mustdeliver on its spirit.

By Tom Andel,Associate Editor

“We encourage you to begintesting slipsheets for all compati-ble merchandise that is shippedto our stores on regional LTL car-riers, full truckload carriers, oryour own trucks. After a fivemonth conversion period, allproduct shipped in this mannermust arrive on slipsheets. We willnot accept palletized freight afterJanuary 1, 1995”.

Thus began a change of life for5,000 Home Depot suppliers earli-er this year. For many of these com-panies, slipsheet usage is anew–even intimidating–proposi-tion. But the thought of losingHome Depot’s business was evenscarier, so most of them are nowstarting to make a go of it. Judgingby the experience of suppliers tothis chain’s Northeast stores duringthe first regional trial period, thechange might be just what the doc-tor ordered.

“We found out quickly that ourdamage decreased by 30% by goingto slipsheets,” says TerryO’Hara, traffic and ware-house manager for CustomBuilding Products. “Thishappened in three or fourmonths. With slipsheets, alift truck operator has to bejust a little more careful.No damage must go toHome Depot.”

But for Home Depot, dam-age wasn’t even the primary

reason for converting to slipsheets.The number one reason was thecost – financial and environmental– to dispose of pallets in a landfill.The cost of new wooden pallets alsofactored in. But why slipsheets? Itcertainly wasn’t a case of love atfirst sight for Home Depot.

“After a brief period of time con-sidering slipsheets, we said, ‘Wow,this looks complicated. Let’s findanother way to solve this prob-lem,’” recalls Pete Cleveland, vicepresident traffic and distributionfor Home Depot. “Then we lookedat pallet exchange, pallet rental,and re-using pallets throughout thesystem. We even looked at sendingour pallets to a mulcher, where wewould bag the mulch and sell itback to our stores. After modelingor testing these alternatives, wedetermined none of them would doanything near what slipsheetswould do for us.”

They were convinced of this afterseeing what slipsheets did for AppleComputer. Apple had a similar onagain/off again introduction to slip-

sheets a few years ago – mainlybecause of the difficulty of gettingtheir suppliers to cooperate.

“Then Apple said, ‘wait, this isn’tthe Apple way, the Apple way is torun through the walls,’” Clevelandremembers. “Then I realized, that’sthe Home Depot way too. We’re notgoing to let the walls stop us.”

Still, Cleveland doesn’t think slip-sheets would have been practicalfor Home Depot five years ago. He’sconvinced slipsheets are a solutionfor the 90s. First, companies

“We found out quickly thatour damage decreased by

30% by going to slipsheets.”–Terry O’Hara, Custom

Building Products.

Some Home Depot vendors moveslipsheeted unit loads through their

warehouses on slave pallets. By keepingpallets on their premises, they save theexpense of shipping and losing pallets.

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Home Depot

weren’t feeling the regulatory heatof environ-mental agencies in the80s. There weren’t the criminalsanctions for pollution there aretoday. Second, he feels today’s tech-nology and equipment – includingthe push/pull attachments and thelift trucks they attach to – makeslipsheets an easier alternative.

MIXED REVIEWS

Vendor reaction to Home Depot’smandate varies greatly. Two-hun-dred fifty suppliers committed tothe program right away. Another200 are recalcitrant non-believers.In the middle are the “wait andsee” people. Some in this latter

group are the LTL carriers.

“They were a problem early on,”says Cleveland. “But our regionalcarriers came on pretty quickly, andevery one of them put equipmentinto their terminals. Most of themhad some experience with slip-sheets, but nobody made the invest-ment for their entire system before.”

One Home Depot supplier,Lakewood Engineering, had theprivilege of riding that learningcurve with the carriers. This manu-facturer of heaters and fans slip-sheeted product right off theassembly line, five years beforeHome Depot made it a policy. ButLakewood was asked to comply

with another request from HomeDepot: direct-to-store deliveries.

“We’ll ship five or six differentmodels to one store during the fanseason, but if the order quantitiesdon’t come across in our basic SKUquantities we must break the loadsdown and rebuild them, “says RoyO’Brien, distribution manager. “Thebiggest problem was getting carriercompliance with the program.”

Lakewood’s loads would go outslipsheeted and wrapped and arriveat the Home Depot stores loose,according to O’Brien. Apparentlythe carriers liked to useLakewood’s shipments as top-freight because products came inindividual cartons. This helped car-riers maintain cube in their trailers.

“This was a common problem withthe long haul regionals,” O’Briensays. “Most of them haven’t invest-ed in the push/pull equipment.Finally the carriers started usingplatens, which stopped them frombreaking loads down. We startedseeing our freight come through atthe other end on slipsheets. Theproblem is you cannot double stackin a trailer with platens. If a carriertells you they can, they’ll increasedamage claims. We try to maintainthe cube for the carrier to one des-tination so they don’t have to splitthe freight down.”

Maintaining trailer cube is especial-ly important with lightweightfreight. Deflect-O-Corporation man-ufacturers plastic injection-moldedproducts –again, top-freight baitfor carriers. Tim Wells, director oftransportation and distribution,says when they palletized this prod-uct for shipment, doublestackingbecame perilous.

“If there are stringers missing, you

Bare Bones Vehicles To The RescueHome Depot’s slipsheet programwas almost finished before it started.Their pilot program began two-and-a-half years ago in the Northeastsection of the country. Each storereceiving dock was supplied with aquick-fork-mount push/pull attach-ment to put on their lift trucks forhandling slipsheeted loads.The problem: every time a load ofslipsheeted goods came in, receiv-ing personnel would have to find a forklift, then attach the slipsheet mechanism.If the forklift was busy pulling an order for a customer, workers had to wait forthe vehicle to be freed up. This meant receiving delays, angry truckers, and ven-dors hit with back charges for the waiting time.“It got to the point where our receiving people in the stores wouldn't hook thesedevices up, “says Matt Pitts, equipment manager for Home Depot. “The programwas pretty close to dying. That’s when we called in Raymond [the lift truck sup-pliers] and Cascade [the attachment suppliers] to design a new concept.”The solution lay in designing a vehicle that would be dedicated solely to handlingslipsheeted loads. They started with a standard Raymond lift truck and modified itto make it more cost effective. The original truck was overqualified for a receivingdock job where high speed and high lift were not requirements.“Home Depot did not want all that versatility,” says Michael Romano, director ofnational accounts for Raymond. “They wanted a design that would preclude itfrom being useful on the sales floor. That’s why they limited lift height to 66 inch-es. Because we didn’t have to outfit the vehicle with all the safety equipment usedon the store equipment, that automatically makes it off-limits to workers on thesales floor. It also took cost out of the unit.”“Now what we have the support of receiving, this program is much easier,”Pitts concludes.

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introduce all types of problems ifyou try to double stack in the trail-er,” he says. “With a slipsheet youalways have a nice solid bottom andyou don’t have to worry about apallet being busted. So as long asyour loads are fairly uniform, theycan still cube out the trailer.”

Deflect-O-Corporation now shipson slipsheets to 10 customers.Wells says it paid off quickly.

“If your product works well onslip-sheets you can cut transporta-tion costs and pallets,” he says. At$5 a pallet, you can spend a prettygood penny. Although a push/pull

mechanism can go for $5,000, thereturn on your money is fairlyquick. When I got wind that HomeDepot was going to require its ven-dors to use slipsheets, the timingwas right for us because we wereready to purchase a couple new lifttrucks anyway. I had the vendoradd the attachment.”

RETURN ON INVESTMENT

Different vendors have differentpay-back formulas, depending ontheir product lines. Super MillworkInc. provides Home Depot withpre-hung interior doors, which arehard to palletize, let alone slip-sheet. Although vice president DougMacMillan didn’t think it could bedone, they gave slipsheets a try.They designed a cardboard bin inwhich ten doors can nest. The slip-sheet goes under the bin. This solu-tion works, but is also costly.

“We had to invest $15,000 in astretch wrap machine, plus the peo-ple to run it” says MacMillan. “Wealso had to invest in the slipsheets,bins, and two attachments. But it hassignificantly reduced truck loadingtime. It used to take 2-1/2 hours toload a truck by hand. Now it takes ahalf hour. I would say we run deadeven, comparing the cost of the pre-vious method with what we’re doingtoday. I could have gotten out of this,but we view our relationship withHome Depot as a partnership.”

Besides, the other pre-hung doormanufacturers aren’t doing it. Thisgives Super Millwork a competitiveedge with Home Depot.

Another challenge that needsaddressing before more vendorsbuy into slipsheets is how to keepproduct on them. Flotec, manufac-turers of pumps and water tanks, is

Carrier Cooperation CrucialSlipsheets aren’t new to carriers, but once Home Depot’s January 1995 slipsheetcompliance deadline kicks in, it may take some time for the LTL carriers to getused to the volume they’ll handle.

“As Home Depot gears up their vendor community we are also equipping ourselveswith whatever is necessary to make handling of slipsheeted shipments easier,” saysBill Graham, v.p. of transportation and operations services for Yellow Freight.“There are techniques for properly handling and stacking slipsheeted shipments.We’re in the process of educating our dock workers in these techniques.”

The participating LTL carriers agree, training is critical to this program’s success.Roadway Express is working with Home Depot in developing training materials–both for Roadway personnel and for Home Depot’s vendors.

“Our sales force will be an extension of Home Depot as they go into Home Depot’svendors and talk to them about what it will take to be successful,” says Bob Obee,Roadway’s vice president of operations, planning, and engineering. “By the time wetake Home Depot’s vendors through our engineered approach, they’ll see thebenefit and come on board.”

That engineered approach entails careful examination of slipsheet specifications.With the additional pushing and pulling slipsheets get in the LTL environment, Obeebelieves they’ll need more durable specimens than are typically used in the truck-load environment. They’re also looking for better ways to secure unit loads.

“With palletized productyou can wrap the stretchfilm around the woodencorners to secure productto the base,” Obee explains.

“You have a harder timedoing that with a slipsheet.Some of the slipsheetmanufacturers have shownus models with interlock-ing corners. On initial test

they look like they’ll be much better able to be locked in for unitization. We’re alsolooking at how many wraps are necessary on loads of this type. But such an engi-neered approach will work or not work based on the effectiveness of the training.”

Yellow’s Bill Graham agrees, noting that LTL carriers are constantly educatingthemselves and their customers on what it takes to meet higher service levels.

Our business is becoming much more service sensitive,” says Graham. “Slipsheetsare just another element in an already complex process.”

Graham is factoring in a learning curve in his assessment of Home Depot’sslipsheet program.

“We’re training to avoid as many snags as we can, but this is a dynamic businessand every trailer ends up with a different mix of freight. Slipsheets add anotherpiece to that puzzle.”

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still trying to perfect a way to stackthese items on a slipsheet thenstretch wrap them. Tandy Caudill,distribution manager, says they’relooking at adhesives.

“Some products aren’t made forslipsheets,” he adds. “It must be astandardized product. With ourtype of products you can’t stackone load atop another [in a truck].That means we can’t cube out thetrailer. But in our warehouse theslipsheets work better becauseloads come in from manufacturingpalletized on slipsheets. We justtake them off the truck and stackthem in the warehouse. When guyspull orders they just take them offthe slipsheets, and you don’t havethe expense of another pallet.That’s why I think you’ll see morecompanies go to slipsheets.”

Lakewood Engineering’s RoyO’Brien agrees. He ran the num-bers on what it would cost hiscompany to ship on pallets. Hiscompany moves 60,000 SKUs ayear. Even with less costly pallets, at$4.50 each, that would mean anannual outlay of $270,000. Withplastic slipsheets, at 86¢ each, thecost is $51,600. Corrugated fiber-board is even less – 56¢ each, or$33,600. His company uses bothtypes of slipsheets to ship to cus-tomers, although Home Depotrequires plastic only.

“We were using 200 lb test corru-gated slipsheets,” he says. “Theseare very easy to dispose of but ifyou don’t catch the lip right there’sa possibility of tearing it. We weregetting two to three turns on thecorrugated slipsheets we kept inour own warehouse. The plasticones have a longer lifetime. Wehaven’t pursued shipping on plasticto other retailers – not because of

cost but because they have to beequipped to handle the scrap.”One of Pete Cleveland’s big sellingpoints to vendors is the cost com-parison between slipsheets and pal-lets. He tells them if they’re ship-ping a truckload of slipsheetedproduct to Home Depot they’re sav-ing about $100.

“Once the equipment is paid for,you get pure savings,” he says.“We’re told the equipment shouldlast from five to seven years. ButI’ve seen push/pull attachments thathave been used for well over ten.”

LESSONS LEARNED

The slipsheets delivered to HomeDepot stores are put in a stack,banded, then backhauled to thechain’s DC. There they’re sortedinto reusable or recycle. Thosedeemed reusable will be put towork in the DC.

“We started with fiber slipsheets,but we realized they wouldn’t workin our environment because of thenumber of uses the slipsheet got,”says Cleveland. “Our New Jersey DChas been doing this the longest and

they think they’re getting four tofive turns on the plastic slipsheets.With fiber we were having failurewith one turn in many cases. In anLTL environment it could get han-dled three times between the ven-

SlipsheetsAdd Stability

Slipsheets aren’t always used to replacepallets. The two can work together informing a stable unit load.

There is a continuing push toward pack-ing more than one thing on a pallet. Youmay add three or four tiers of one prod-uct to three or four of another. But acorrugated box is strongest as its cor-ners and weakest in the middle. That’swhy, if a box in the bottom layer is sup-porting one above it with its middle sec-tion, you don’t have the strongest loadyou can have.

Putting a slipsheet between such layershelps distribute the load so the bottomboxes can better support the upper tiers.Slipsheets can also tie the tiers of a loadtogether, adding stability.

For example, if you column stack, keepin mind what we said about boxes beingstrongest at their corners. Columnstacking is the most economical way toship the most product in one unit load.Using slipsheets between tiers maxi-mizes the stability of such a load.

Information provided by Steve Beshore,program manager for packaging sys-tems research and development atInternational Paper’s PackagingInnovation Center, Middletown, NY.

“The pallet’s been aroundfor over 50 years, and I’mnot sure there are manyinventions that have auseful life above that.

I tell my people if they’vebeen doing something for

five years it’s probablywrong now.”

–Pete Cleveland,Home Depot

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Home Depot

dor and our store. With that con-stant re-use the tabs would pull off.And if there was any moisture at allin any of the trucks along the way ittended to weaken the fiber.”

One of the biggest surprises toHome Depot involved the pooracceptance of equipment – by theirown stores. The chain uses quick-fork-mount push/pulls attached tosit-down counterbalanced lifttrucks. These weren’t well receivedat the stores because the workersweren’t used to maneuvering lifttrucks in and out of the relativelyclose quarters of their store rooms.Electric pallet jacks were their toolsof choice.

“We worked with Cascade andRaymond Corp. to come up with avehicle that was more user friendlyto our receiving department,” saysCleveland. “Once we put that equip-ment in, our stores turned aroundcompletely on slipsheeting. Theywent from hating it to loving it.”

As for carriers, Cleveland pleadsguilty to naiveté for expecting carri-ers to welcome this concept withopen arms. It took the success ofits regional carriers in theNortheast to convince the othercarriers this could be done.

“Once our regionals saw the suc-cess TNT Redstar was having, theyagreed to support what we weredoing.”

As of January 1st, Home Depot’sslipsheet mandate will be in fullforce across the country. PeteCleveland feels their regional trialperiods helped put them a stepahead of the competition in chop-ping away at their pallet problems.

“The pallet’s been around for over50 years, and I’m not sure thereare many inventions that have a

useful life above that,” he argues.“I tell my people if they’ve beendoing something for five years it’sprobably wrong now.”

Home Depot’s philosophy of com-petition will continue to drive theirslipsheet program. It’s built upon asmoother, faster-flowing, less costlysupply chain. After all, Clevelandconcludes, “It’s not us against ourcompetitor; it’s our supply chainagainst our competitors.” T&D

Copyright © 1994by Penton Publishing, Inc.,Cleveland, Ohio 44114Integrated Warehousing &Distribution

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Quaker State Oil

LIFT TRUCKATTACHMENT ELIMINATESPALLET USE –QUAKER STATE OIL

By Richard Rix,Assistant Editor

A curious dilemma exists in onearea of materials handling. If youuse pallets, you face problems ofhaving to store them and maintainsome degree of inventory control. Ifyou don’t use them, such opera-tions as loading trucks and railcarscan prove costly and laborious.

Pallet handling was one of the keyareas in which Quaker State OilRefining Co. of Canada Ltd. focusedattention when it moved to a new40,000-sq. ft. plant at Burlington,Ont., recently.

This company had completely up-dated its production facilities andnow looked for a more efficientway of handling one of its mostpopular product lines: Motor oilin 1-qt. cans packed 24 to a car-ton. What it required was a methodof handling that could be fully inte-grated with pallet use but which

could be fully automated where itwas unnecessary to use pallets. Themethod it finally chose was to useLoad Push/Pull lift truck attach-ments from Cascade Hydraulics(Canada) Ltd., Mississauga, Ont.

Basically, the Load Push/Pull unit ismounted on the front of a suitablelift truck and handles loads onpaper slipsheets. (The method canbe called palletless handling orunitized-load handling). Simplydescribed, the unit consists of aface plate that extends and retractsby means of a pantograph mecha-nism; a gripper bar and jaw toengage the lip of the slipsheet; andtwo oversize forks called platens.

PUSHES ON, PULLS OFF

In operation, the face plate pro-vides a forward action to push aslipsheeted load off the platensonto the floor (or pallet) or ontoanother load. Its pulling action,on the other hand, is accom-plished by the gripper bar closingover the protruding lip of the slip-sheet, automatically pulling theload onto the platens when theface plate is retracted. Since theday when it went into operation,the Load Push/Pull unit hasproven to be extremely efficientand reliable – the ideal comple-ment, in fact, to Quaker State Oil’snew production facility.

PLANT BLENDS, PACKAGES OIL

The facility itself is responsible forblending and packaging motor oilsand lubricants and shipping themby truck and rail to the wholeCanadian market.

Recently introduced to an oil blendingand packaging plant, this lift truckattachment enables handling operatorsto match production capabilities.

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Quaker State Oil

At the beginning of the process, therefined product arrives at the plantfrom the parent company’sPennsylvania refineries in tankcars. From these cars it is pipedinto tank storage, blended accord-ing to specifications and packaged,all fully automatic. The packageswhich the Load Push/Pull attach-ments will handle come off the pro-duction line in such a way that fourlayers of ten cases on a slipsheetcomprise a load. Each load meas-ures about 50 cu. ft. and weighsmore than 2,400 lb.

Two of the lift trucks operating atthe plant are fitted with the attach-ment and each operates in thesame way: It pulls a load onto itsplatens, transfers the load to thestorage area and offloads intostacks up to four loads high. Then,when they’re called for, these samelift trucks transfer the loads totrucks and railcars for shipment.

SAVES TIME LOADING TRUCKS

Not only can all these operationsbe achieved without using pallets,

but transferring the loads intotrucks and railcars can be accom-plished in a fraction of the time ittakes to handle them manually.

“Speed of operation is the mainreason we chose the LoadPush/Pull method,” acknowledgesPat Irvine, plant manager of QuakerState Oil. “Before, it would takefour men one hour to load a truckmanually, removing containersfrom a conveyor in the truck. Nowit takes one man just 20 minutes toload a truck using a forklift fittedwith the attachment and we’ve elim-inated the use of that conveyor. Ifthe customer still wants pallets –and many of them do because oftheir own materials handling meth-ods – we’ll just place the slipsheet-ed loads on the pallets.”

The cost factor has also been animportant consideration. The slip-sheets cost just 85 cents eachwhereas the cost of a pallet issomewhere in the region of $10.Multiply this twentyfold (the aver-age truck load consists of 800cases and it takes 20 slipsheets toaccommodate them) and you havecosts of $17 versus $200. Ofcourse, the slipsheet is non-return-able whereas the pallet deposit isrefundable, but the higher degreeof efficiency that accompanies theslipsheet’s use more than compen-sates for this higher cost factor.

REDUCES PALLETINVENTORY PROBLEMS

The company also finds it’s beenfreed from the vagaries of having to

Stacking. . .

After stacking the slipsheeted load, thelift truck operator reverses his truckwhile at the same time extending thePush/Pull attachment. In this way, theface plate holds the load in place whilethe platens are retracted.

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maintain some degree of inventorycontrol over its pallets. ExplainsIrvine, “Generally speaking, you’dget your pallets back – eventually.But say a distributor is purchasingon a monthly basis. He may holdthe pallets until he’s got a full loadseveral months later and then shipthem back all at once because it’scheaper for him.

“Then again, he may get $12 eachelsewhere so you wouldn’t getthem back at all. There’s really noway of maintaining an efficientinventory control.

“Take as an example the figuresrelating to pallets we still use.Some-where in the region of2,000 pallets went out in the firstquarter of this year so you’dexpect somewhere near the samefigure to be returned in the sec-ond quarter. In fact, I doubt ifwe’ve had 500 returned. I evenhad to buy 700 or 800 more. NowI’m just hoping I won’t get 1,200pallets returned in the next threeor four months because I’ll have aplant full of pallets.”

SLIPSHEETS NEED LESS ROOM

This raises another important point:The physical size of pallets com-pared with slipsheets. The area ittakes to store pallets is significant,costs money and reduces plant effi-ciency. Slipsheets, on the otherhand, take up very little space.

Even in use, the comparatively in-significant thickness of slipsheetscan be an important consideration.When several are used in a stack,

for example, the uppermost layeris that much lower in the heat-risearea, and there is less risk ofobstructing a sprinkler system. Intransit, too, if the customer does-n’t want his load palletized, slip-sheets can help protect it withoutcontributing significantly to its height.

The slipsheets Quaker State Oiluses are supplied by Abitibi PaperCo. Ltd., Toronto, and CanadianInter-national Paper Co.,Burlington, Ont.

WEEK’S TRAINING NEEDED

Any competent forklift truckoperator can safely and efficientlyoperate a truck fitted with the LoadPush/Pull attachment after a week’sconstant driving, according toIrvine, “He may think he can do itright off the bat, but he’s got to pickup additional skills.

“Especially critical is an exactjudgement of height when stack-ing,” continues Irvine. “The frontcorner of a load being stacked uphigh is blind and the operator must

. . .Unstacking

To unstack, the attachment’s face plateengages squarely against the load withthe edge of the slipsheet in the gripperjaws. Then, as the attachment retracts,

the gripper closes and the load ispulled onto the platens.

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coordinate his judgement of heightwith being able to push the load offand pull away at the same time.Don’t forget, too, he always has theweight of the load on the platenswhereas with a straight forklift,once he lowers the load he justpulls out.”

Stacking at Quaker State Oil’s plantis restricted to four loads high, butthis is not due to any limitations onthe part of the trucks or attach-ments. Rather it’s mainly because ofthe weight on the bottom layer.

STRAIGHTFORWARDCONSTRUCTION

The construction of the Load Push/Pull unit is quite straightforward. Itconsists of a base frame assemblyin which is mounted a pair of dou-ble-acting hydraulic cylinderswhose circuitry is connected to thelift truck’s hydraulic system througha valve assembly.

The hydraulic cylinder rods areattached to the pantograph arms byheavy-duty linkage, and the arms,in turn, are linked to the load face

plate. When hydraulic pressure isapplied, the arms open (stretchout), pushing the face plate forwardto the outer end of the platens.

Conversely, when pressure is appliedto the opposite end of each cylinder,the arms close and pull the faceplate back against the frame assem-bly. The gripper bar, at the sametime, has closed over the protrudinglip of the slipsheet and pulls the loadonto the platens as it retracts.

PLATENS COMEIN VARIOUS SIZES

The platen arms consist of twopolished and tapered platens, 48in. long and 15 to 20 in. wide,depending on model and capacity.Multiple-fork versions are availablethat have been specially designedfor the food industry but which areused for other operations. Bothmodels can be supplied with side-shifting capabilities.

Several versions of the Load Push/Pull units are available, both in the4,000-lb. capacity Quaker State Oiloperates and in the higher 6,000-

lb. category. In this way, differenttypes of lift trucks with variouscapacities can be accommodated.Various modifications and acces-sories also exist, such as a tiltingface plate for handling sensitiveloads and an attachment forretrieving slipsheets from loadsafter stacking. There are even camswhich can be mounted at the endof the cylinder rods to prevent theforks from protruding beyond theedge of the load and damagingloads already stacked, an impor-tant consideration with loads ofvarying depths.

REQUIRES LITTLEMAINTENANCE

From the maintenance point ofview, the Load Push/Pull unitrequires very little servicing,according to Irvine. “It’s very main-tenance free, though like any otherpiece of equipment, you have tohave a good maintenance programto keep it that way.”

At the end of each day, the plant’sown maintenance man carries out a

A significant chunk of floor space isrequired to store pallets (left) whereasthe hundreds of slipsheets shownbelow take up little room.

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Quaker State Oil

10-minute inspection on each ofthe Load Push/Pull attachments.Mainly he concentrates on thehydraulic hoses and checks that thegripping mechanism hasn’t beentwisted. Ironically for Quaker StateOil, the attachment requires nomajor lubrication.

Once a month, a technician fromJ.H. Ryder Machinery Ltd., Toronto,(who supplied the lift truck andLoad Push/Pull attachment com-plete) visits the plant and checksover the equipment. He’s also oncall should any problems arise thatQuaker State Oil’s maintenanceman cannot solve.

FULLY INTERCHANGEABLE

All told, the plant uses four lifttrucks – the two fitted with theLoad Push/Pull attachment andtwo which operate as standard lifttrucks. All the lift trucks are iden-tical (Model EC 500-40 from ClarkEquipment of Canada) and are fit-ted with the hydraulic controllever required to maneuver theattachment, so the attachments arecompletely interchangeable. Thisoperation is carried out in tenminutes, the attachment beingconnected by just two quickchangemounting hoods and the hydraulichose coupling.

Needless to say, using a Load Push/Pull attachment does impost agreater battery drain than just oper-ating a standard forklift truck.When powering the attachment, thebattery is directly responsible for itsforward and retracting motion aswell as the other functions of astandard truck.

Even so, by using the largest batterypossible in its lift trucks. QuakerState Oil finds that, on a 24-hour

charge, it’s generally able to com-plete an 8-hour shift operating theattachment. If it’s really pushed,according to Irvine, the companyrotates the attachments among itslift trucks, because a battery whichis too low to power a LoadPush/Pull unit will still run a stan-dard lift truck reasonably well.

Irvin points out, too, that thereare products for which his com-pany will continue to use pallets,because of their greater stabilityin handling such loads as QuakerState Oil’s 46-gal. drums, 35-lb.pails and 120-lb. kegs. But formoving loads packed in cartons,Irvine is convinced the LoadPush/Pull unit is the best attach-ment there is. “To my knowledge,nothing is more efficient in thisarea,” he says. “It’s certainlysuperior to forklift and pallets forour purposes.”

Reprinted from MaterialsManagement & Distribution,July 1977.

©1977 Maclean-Hunter Ltd.

82

Jewell Foods, Inc.

PRIOR TO SLIPSHEETSUnited Fruit & VegetableAssociation Committee MeetingWashington, D.C. –September 26, 1977

speech delivered by JimChase, President of JewelFoods, Inc., Chicago, IL.

I would like to personally thankall of you for allowing me tospend a short time with you atyour annual meeting and sharewith you our thoughts in the dis-tribution area at Jewel Food Storesregarding the use of slipsheets inreceiving and shipping.

First, perhaps a little informationalbackground about Jewel FoodStores as one of your customers.We operate approximately 186stores in the Chicagoland area inaddition to super-markets in Iowa,Indiana, Michigan and Wisconsin.

Our primary market, of course, isChicagoland and suburbs where wehave the largest share of the foodmarket – 30 to 35% depending onwhich Chicago newspaper youread.

So much for information on us andlet’s, for a few minutes, discuss ourfeelings and perceptions at JewelFood Stores on slipsheeting.

We at Jewel, for the last year, havebeen pursuing vigorously withgrowers and packers, particularlyin the Florida citrus area, the slip-sheeting concept and completed atour of the citrus packing plants incentral Florida discussing this issueand arranging for test loads withthe different citrus packers.

We now have in our produce distri-bution center, two slipsheetmachines and an additional two are

on order for 1978 delivery. Nowlet’s take a look at the differentaspects and pickups of going intoslipsheet material handling fromthree different perspectives in thetotal distribution process. Theseare the grower, carrier and thereceivers. Then I will address someopportunities that need to bethought about and concentrated on.

I will close my remarks with someblue sky projections we have atJewel for product flow concepts rel-ative to shipping the product to ourstores and ultimately the consumer.

FIRST, THE SLIPSHEETADVANTAGES FOR THEGROWER-SHIPPER

1. There are large labor savingsto be captured at the grower,packer ends of the businessas exhibited in the Floridacitrus packers conversion toslipsheet handling. As wagesget higher and higher forlabor to perform the dockand loading function at thepacking house level, this areais prime for improved materi-al handling through the useof slipsheeting.

The use of automatic palletizingmachines onto slipsheets tofurther eliminate labor arecommon and one or twoslipsheet fork truck operators are common in running anentire packing house dock andloading operation. Labor is alsosaved in loading a magazine ofslipsheets versus loading a pal-letizer magazine with pallets.One magazine of slipsheets mayhold as many as 100. A strap-ping device can also be incor-porated into the automatic pal-letizer to secure the product.

2. There are no storageproblem of pallets when ina slipsheet operation – slip-sheeting at packer level great-ly increases packer plant uti-lization of space when you donot have to store pallets.Estimates are 15-20% spacesaving in a plant using slip-sheets versus pallets.

3. Sanitation problemsthroughout the distributionsystem are greatly reduced bynot having pallets whichdecrease the USDA by RDArisk at plant level. It is fore-seen that in our industry thatthe standards and interfacedwith these governmental agen-cies will continue to increasein the future, so the sanitationpickups with slipsheeting are areal operating benefit andconcern. As it is commonlyknown that the wood pallet isone of the greatest vehicles ofrodent and insect infestationin the distribution centers.There is significantly less dol-lar investment throughout thetotal distribution system by theuse of slipsheets freight han-dling compared to the $5 -6wood pallet.

4. There is improved in-plantsafety in handling slipsheetedproduct versus pallets withwood splinters and exposednails, which can convert to dol-lar savings in absence and dis-ability claims against the plant.

Less in-plant building andequipment damage will occurmoving your product aroundon slipsheets. Damage towalls, machinery, doors, con-duit, etc.

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Jewell Foods, Inc.

5. Trailer weight cubutilization can be increasedby the pallet weight of 1400-1500 lbs. of additional freightif slipsheeted versus pallets.Actual gross weight pickupcan be higher figuring spacepicked up timers case weight;if it still falls into legal trucktransit weights.

Additionally, as is well known,truckers prefer unitized loads,slipsheets or pallets versusfloor loads and in time ofmotor carrier shortages, theplants that are unitized gener-ally get preference by the driv-er in accepting their freight.

6. Reduced product damagehas been noted by our experi-ence in slipsheets versus pal-lets particularly in the loadingand unloading process, due topallet abrasion against cases.

7. Reduced capital investment– Currently Jewel Food Storesis spending almost one milliondollars per year on wood palletreplacement due to a variety ofreasons such as receivingpallets in poor repair, stolen atthe store level and having ourgood pallets exchanged withdirect delivery vendors fortheir bad pallets at the storelevel. Obviously with slip-sheets, the massive dollarinvestment and continuedreplacement of wood palletswould be significantlyreduced. There are much lesslabor dollars expended inreceiving and storing slip-sheets versus pallets.

There are some of the signifi-cant advantages for a grower-shipper to convert to slipsheetoperations.

Now let’s look at the advantageson our side of the business – thereceiving warehouse. A numberof your stated advantages alsoapply to us as your receivingwarehouse customers.

RECEIVING WAREHOUSEADVANTAGES

1. It is suggested to secure thefreight in transit and secure asuitable slipsheet unloadingoperation that the slipsheetproduct be taped or boundor in some cases, with theuse of glue.

2. As mentioned in your pickups,we also share the improvedsafety aspects of handling slip-sheets versus pallets – lessemployee accidents andreduced absence and disabili-ty costs and minimized OSHArisk violations. Broken andunsafe pallets constitute anOSHA violation.

3. Reduced product damage fromabrasion on the side of the car-tons in the unloading process.

4. Some increased dock spaceutilization with a reducedamount of excess pallets inthe area. Increased warehousespace utilization if productsare stored on slipsheets andare able to be double stacked.

5. Many warehouses have out-side unloading services (lum-bers) which are in manycases, unreliable and theiremployees are a safety andliability risk. Getting freightoff of the floor onto slipsheetswill reduce our dependencyon them and ultimatelyreduce or eliminate the needfor this service. Being too

dependent on lumbers forunloading can put a ware-house in serious jeopardyregarding dock turnover if thelumber service becomes unre-liable or disappears.

6. In our first few railcars of slip-sheeted produce, we foundsignificant labor savings thereversus the former floor loadedrailcars – example, a large floor load rail car would takea man eight hours to unloadand when we received it slip-sheeted, it took 3-31/2 hours.

OTHER VERY PERTINENTINFORMATION ON WAREHOUSERECEIVING – OF SLIPSHEET-ING VERSUS CURRENT NON48" X 40" GMA PALLETS ISAS FOLLOWS:In 1976, we received approximately10,000 non 48" x 40" pallets atan approximate cost to us the cus-tomer, and ultimately the consumerof $50,000.

Granted, the material handlingadvantages in receiving and dockturnover are received from non 48"x 40" pallets, but they presenttremendous costs to us on our endof the distribution cycle:

SOME OF THESEDISADVANTAGES ARE:1. Tremendous increased costs to

our business because we con-sider non 48" x 40" pallets onetrip throw-aways and they arenot compatible with the groceryindustry standard as wouldyour product being received ona 48" x 40" slipsheet.

2. We now unload and stack no48" x 40" pallets onto a 48" x40" pallet wherever possible

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Jewell Foods, Inc.

but under numerous circum-stances it creates an unsafecondition throughout thematerial handling process par-ticularly if double stacking orusing metal reserve storageracks leaving the receivingwarehouse vulnerable to acci-dent and disability risk as wellas OSHA violation.

3. Our labor is approaching $9per hour—expended daily tosort, transfer, stack, store andhopefully finally get rid ofthese non 48" x 40" pallets.

4. Within the last two years wehave had increasing difficultyin getting rid of them.Currently we give them awayfor free. At times we could notget rid of them at all and wefeel eventually we will have topay to get rid of them. We feelthe future is in slipsheeting ona sheet compatible with the48" x 40" grocery industry orin some cases, a conversion tothe newly approved grocerypallet council softwood 48" x40" pallet for areas wherehard wood is unavailable.

5. Our pallet repair—sortingfacility costs have increased 4times since 1972. In 1972 wehad 4 nailer-sorters—todaywe have 12 nailer-sorters tokeep up with all types of palletrepair, sorting and expeditingof non-usable pallets. Weapplauded in the past, yourconversion from floor loadproducts to the non 48" - 40"pallet, but we encourage youto look at slipsheeting andhow does it fit into the totalfood distribution cycle fromfield to customer.

SOME ADDITIONAL CHALLENGESAND INFORMATION FOR ALL OFUS TO WORK ON TOGETHER.1. Numerous produce case sizes

and configurations do notconform to the 48" x 40" gro-cery pallet or slipsheet designso as to be compatible withthe major food distributionpallet system. To be compati-ble with our system and ourslipsheet forks, we need tohave a 40"-48" slipsheet. It isour opinion that the retailindustry can adjust, order andsell any container size youconvert to if it is compatible toa 48" x 40" slipsheet. ExampleI believe in some commoditiesthe gross case weight hasremained un-changed formany years. Yet, in most laborenvironments including ourown, it costs us the same tohandle a 25 lb. case versus a50 lb. case—we should moveto larger case weight sizes. I,understanding objectives inthis area. I suggest you exam-ine your shipments and youprobably will find the largestshare of your product goes tothe large volume retailer whouses the 48" - 40" dimensionshipment mode.

2. In looking at future packagingin light of handling and dam-age reduction further studyshould be conducted on thefeasibility that would lend thecases to interlocking tierstacking to promote stabilityof frights on the slipsheet intransit and in the unloadingprocess without damaging thecontents, or additional manuallabor at the warehouse will beneeded to straighten the load

before we could unload it.Taping of the top tier of freightis recommended or strappingor glue.

3. Caution should be used in theselection of the proper slip-sheet on its size and lip sizeand caution should be used inthe selection of the properslipsheet on its size and lipsize and additionally, howcooler temperature, moistureand humidity will affect it inthe distribution cycle.

In our experiences recentlywith the Florida citrus slip-sheet receipts, we are discov-ering a large amount of deteri-oration of the slipsheet due tothe above reasons. We arenow working with them ontesting moisture retardantplastic coated sheets or fullplastic sheets. Be careful youtest sheets properly beforecommitting to a mass pur-chase. Wherever possible,these sheets should be recy-clable either to make moreslipsheets or mixed with cor-rugated for recycling.

4. We suggest from experience,before you buy a particularslipsheet machine or a conver-sion kit of an existing forktruck, that you test severalbrands before you purchase.Some work better than others.Find out what works best foryou and your products. Arecent bid we had to convertan existing for truck to a slip-sheet attachment was$5,700.00.

5. As a point of information togive an example of the foodindustry’s interest and shift

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Jewell Foods, Inc.

from pallets to slipsheet, wewere recently served notice byone of the nation’s largestmanufacturers that within 2-3months they would be out ofpallet deliveries and into fullslipsheeting in our area.

In conclusion, we at Jewel wouldbe happy to work with any of you intest shipment loads. We will pro-vide documentation on the condi-tion of the receipt and if you want,even pictures.

We, at Jewel, are seriously lookingin the future to design stores andreceiving docks in a manner whichpromotes the end of the pallet as amajor device to ship groceries tothe store on and will be looking atconducting tests in slipsheet receiv-ing at store level. The future, webelieve, is definitely slipsheetingand other forms of unitization.

We think for a number of reasons,in time the sanitation, safety, spaceutilization of trailers, warehouseand store back room and huge dol-lar investments in pallets, that thewood pallet use as we know it, willbe greatly digressed in the total dis-tribution system.

Thank you very much for thisopportunity to speak with you andif you are in Chicago, we extend aninvitation to tour our warehousedistribution facilities. Thank You.

Plain sheets in volume 50 – 90¢depending on strength

Plastic sheets $2.00 - $3.00 –must be recyclable

86

Pik'd Rite, Inc.

UNITIZING 30-LB CANSSAVES 75% LABOR –PIK'D RITE, INC.Slipsheet shipment of net-wrapped loads eliminates palletinterchange, lessens damage.

Anthony J. Grcich,President

Larry Grcich,General Manager,

Pik’d Rite, Inc.Karl Robe,Editor-West

NEW SOLUTIONSTO PLANT PROBLEMS

Problem: Pik’d Rite, Inc.,Escalon, CA, wanted to mechanizeand unitize all handling and ship-ping of frozen fruit products inretail-size cases and 30-lb cans.Particularly tough to handle werethe 30-lb tins of frozen berries.When stacked in the rail cars ortrucks, loads would shift in transitand covers would sometimes comeoff. Stacks were unstable, andinjuries from handling fallen stacksat the receiving end could notalways be avoided.

Solution: Pik’d Rite stacks unitloads of both cased goods and canson slipsheets placed on their cap-tive 48" x 40" pallets; unitizes theload by wrapping it in polypropy-lene netting; and stores the unit-load 4-high in the freezer. At ship-ping time, a push/pull attachment isput on one of the fork trucks (amatter of 10-15 min).

For shipment, the net-wrappedunit-load is pulled off the palletonto the forks, taken into the vanor car, and pushed into place. Atthe receiving end, fork trucks

with push/pull attachmentsunload the shipment.

R esults: Compared to manualloading of 30-lb cans, labor savingsare about 75%. Shipping damage,from load shifting and loosenedlids, has practically been eliminat-ed. Unit-loads can be stacked 4-high without aids such as cornerposts or ties, plus extra labor. Theexpense of returning pallets and ofdamage and loss during shipmenthas been eliminated. Majorreceivers likewise benefit in lowerlabor and damage costs.

Push/Pull® attachment for forktrucks is described in literatureavailable from Cascade Corp., P.O.Box 20187, Portland, OR 97220

“Tension-Net” polypropylene net-ting for unitizing loads of cans,cases, trays, pails, or drums isfurnished by Conwed Corp.,Plastics Div., 770-29th Ave. SE,Minneapolis, MN 55414.

Sidewinder II® system, whichcan be programmed in anydesired pattern for unitizingloads with film or netting, isdescribed in literature availablefrom Infra Pak (Dallas), Inc.,4911 Cash Rd., Dallas, RX 75247.

Polypropylene netting unitizes 80 cans. Load is removed by gripping the slipsheet,and is placed in car in less than a minute

Reprinted from April 1980Food Processing

87

Simplot

ON-THE-JOBAPPLICATION REPORT

Caldwell, Idaho

SHIPMENTS INCREASE TWOMILLION POUNDS WEEKLY

J.R. Simplot Company, one of theworld’s largest processors of frozenand dehydrated potatoes, ships asmuch as two million pounds ofproducts daily. Speed, reduction ofproduct damage and labor are sig-nificant requirements when handlingsuch large volumes of product.That’s why Simplot has installed thefood industry’s most modern pal-letized operations at their Heyburnand Caldwell, Idaho plants.

The company’s palletizing systemwas first installed at Heyburn in1970 and it resulted in dramaticimprovement in product handling.Production through the warehouseincreased up to two million poundsper week and product damage wasreduced approximately 75%.Consequently, the same system hasbeen installed at Caldwell.

An integral and vital part ofSimplot’s palletizing operations hasbeen the use of Cascade’s LoadPush/Pull lift truck attachments.They are used exclusively in prod-uct handling at both plants.

PALLET COSTS CUT IN HALF

Volume handling of Simplot prod-ucts starts when cases are movedby conveyors from the processingplant to a palletizing center. Thecases are fed into an automatic pal-letizer which stacks a double cubeload on a wooden pallet nine casesto a tier, twelve tiers high. A doublecube load starts with a solid, re-usable fiber slipsheet placed on the

loads two high in storage – a totalof 24 tiers.

CASCADE LOAD PUSH/PULL INCREASES PRODUCTION

The task of efficiently handling up to60,000 cases per day of Simplot

products is capably handled byCascade’s Load Push/Pull.

pallet for a stack of three tiers thenanother slipsheet and three moretiers, etc.

A lift truck equipped with Cascade’sLoad Push/Pull attachment picksup the load on a wooden pallet andmoves it to frozen storage. Thecomplete double cube stacking andlift truck loading operation takesless than two minutes. By usingreusable slipsheets instead ofwooden pallets for the cube load,Simplot estimates their total palletcosts have been cut in half.

The double cube is delivered onthe wooden pallet to frozen storageby the Push/Pull equipped lift truckand is carefully maneuvered intoposition. The face-plate of the LoadPush/Pull is then extended andpushes the load off the platens asthe lift truck backs away. With theuse of corner angle stacking aids,Simplot can stack the double cube

SIMPLOT

PALLETIZING

OPERATION &CASCADE’S

LOAD PUSH/PULL

REDUCE PRODUCT

DAMAGE 75%

88

Simplot

J.R. Simplot Company automatically palletizes double cube loads of 108 casesfor frozen storage. Cascade’s Load Push/Pull hauls them away from the palletizing center.

Cardboard Slip Sheet Pallet

Cardboard Slip Sheet Pallet

Cardboard SlipSheet Pallet

Wooden Pallet(For use in Cold Storage Warehouse)

Cardboard SlipSheet Pallet

Single CubeLoad

Double CubeLoad

One tier}

89

Simplot

CASCADE LOAD PUSH/PULLELIMINATES TWO MEN

At shipping time, the double cubeload is picked up on the woodenpallet from frozen storage and driv-en to the rail or truck loadingdock. At this point, the platen armsare removed from the wooden pal-let and the push plate is extended.The Load Push/Pull is then raisedso the attachment’s gripper barlocated at the bottom of the faceplate can seize the leading edge ofthe slipsheet. After thegripper bar has firmly clamped theslipsheet, the load is pulled backonto the platens and driven directlyinto the railcar or van. The use ofthe Load Push/Pull for these opera-tions reduces the risk of damagewhich often occurs when runningchisel forks underneath the load.

When loading a railcar, the doublecube load is placed in the car twocubes high. For truck loading, oneand one-half cubes or nine tiersare removed from the twelve tierdouble cube load and positionedin the truck.

This entire procedure, including carloading, requires only one man –the lift truck operator. Previouslythree men were required to performthese same functions – a driver andtwo people to stack and unstack.

The old hand-stacking method ofloading a railcar took 1.5 days (12man hours). Now, with a LoadPush/Pull equipped lift truck,Simplot can load a rail car in lessthan a day (7.5 man hours).Another advantage of mechanicalloading is the reduction of productdamage in transit. This is due to thetighter packing in rail cars or vanswhich in turn reduces the amountof carton movement.

With the addition of corner angle stacking aids for protection againstcrushing, Simplot can stack double cube loads two high in storage.

Cascade’s Load Push/Pull stacks double cubes two high in frozen storage.

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Simplot

With a firm grip, the Load Push/Pull pulls a stack of cases onto the platen arms for delivery to loading docks.

Here’s how they used to do it! It tookthree men to load a car or van, plus

others to operate a fork lift or conveyor.With the Cascade Load Push/Pull, it

takes only one man.

91

cP.O. Box 20187

Portland, Oregon 97220800 CASCADE (227-2233)

www.cascorp.com

Simplot

SIMPLOT CUSTOMERREDUCE COSTS TOO

According to R.S. Farish, vice presi-dent of Simplot sales and market-ing, the palletizing system has beenenthusiastically received by Simplotcustomers. Their enthusiasmis due to:

1) Increased unloading speed.This faster handling virtuallyeliminates danger of thawingduring unloading of shipmentsand helps prevent demurragecharges.

2) Labor is cut to a bare minimum.

3) “No return” slipsheets enablecustomers to use them in theirown storage operations.

4) Handling of frozen fries incube loads greatly reducesdamage to this brittle productwhich is usually incurredwhen cases are handled indi-vidually. Avoiding this damageprovides maximum servingsper pound of product.

For additional information onCascade Load Push/PullAttachments go to: www.cascorp.com

It takes less time and two less men to load a railcar or truck with a Load Push/Pull.Here you see the lift truck operator using the Load Push/Pull face plate to tighten

the load in a railcar.

92

Northern Fruit Co.

ON-THE-JOBAPPLICATION REPORT

Wenatchee, Washington

A few years ago Northern FruitCompany, Inc., a cold storage andfruit processing facility located inEast Wenatchee, Washington, wasconfronted with the need to opti-mize their production and handlingsystems. Several areas to look atwere how to increase their dockand storage capacities, how toincrease product flow through thedock and how to minimize the fruithandling and resultant productdamage. Their products, consistingof apples and pears, are delicate tohandle and perishable.

The three and one half (3.5) hoursit took to manually load or unloada standard 40' truck van was amajor time consumer. Lengthytruck turn around time for the driv-er was also a problem. Pallet stor-age, pallet repair costs and spaceconsumed during shipment andstorage were additional factors.

To Northern Fruit the obvious solu-tion was the implementation of slip-sheets into their handling, storageand shipping system. This methoduses a 40" x 48" slipsheet which isautomatically placed on a pallet bya slipsheet feeder machine after thefruit is boxed and ready for stack-ing. The boxes are stacked seven(7) per layer and seven (7) layershigh on the slipsheeted pallet in aninterlocking pattern. The ‘unitized’load is then strapped and woodencorner- posts installed. This then isthe storage unit, averaging about2,100 pounds.

Before shipment the corner-postsare removed. The wooden palletremains at the warehouse while the

product is handled and shipped onthe slipsheets.

To handle these unit loads from thepalletizer through the storage opera-tion and shipping, a cushion tired lifttruck is used. This truck operates onLP gas and is equipped with aCascade “Load Push/Pull” attach-ment. The push/pull is equippedwith 15" wide platens which alsoallows handling of product on wood-en pallets as well as on slipsheets.

A sideshifting feature on theCascade Push/Pull allows easymaneuvering during the pick upand placement of the load, whichminimizes the drivers need to repo-sition the lift truck.

Northern Fruit has put into processa unique combination of conven-tional pallets and slipsheets. Theslipsheet method allows them toincrease their handling capacityand speed up production, particu-larly beneficial during the peakseason. They have increased pro-duction from 2,000 boxes a day, afew short years ago, to 7,000 boxesthis past season. A productionincrease of 250%!

Truck turn around time at the dockis minimized. One 40' van can beloaded by one lift truck in thirty(30) minutes. Two lift trucks canbe used to further reduce loadingtime. Warehouse capacity is alsoincreased by this method.Previously loads were only stacked15 boxes high, by the new methoddescribed they are now stacking 21layers high. A storage capacityincrease of 40%.

Implementation of the slipsheetmethod in conjunction with theCascade Load Push/Pull attachmenthas streamlined the Northern Fruitoperation. Improved productionefficiency has minimized producehandling while increasing storageand shipping capacities.

Northern Fruit Company is yetanother example of a progressiveorganization realizing increasedproduction and profits’ by applyingnew material handling techniques.

For additional information and spec-ifications on the complete line ofCascade Load Push/Pull attachmentscontact: Cascade Corporation—see end of Article 8.

Cascade’s Load Push/Pull. . .helping to boost production and profits at Northern Fruit Co.

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Northern Fruit Co.

INDUSTRIES USINGPUSH/PULLSFOOD PROCESSING

CadburyCalifornia Packing CorporationCampbell SoupCarnationCarnationCargilCoast Oyster Co.Colonial SugarContadinaDavid ProcessingDel MonteDomino SugarFrito-LayGeneral MillsGeneral MillsGreen GiantHunt-Wesson FoodsHormelH.J. HeinzH.J. HeinzHillsHunt-WessonJ.R. SimplotJ.R. SimplotJ.R. SimplotKal-KanKeebler CookiesKellogg CompanyKraft FoodsKraft FoodsKraft FoodsKraft FoodsLibby, McNeill & LibbyMaple LeafNabiscoNabiscoNabiscoNestleNestleNestle GermanyRalston PurinaRalston PurinaRodger CannerySenca

Lecmceister, U.K.

Sacramento, CALos Angeles, CAJefferson, WIAmsterdam HollandSouth Bend, WAGrammercy, LARiverbank, CAWalla Walla, WAAlameda, CANew Orleans, LABakersfield, CALodi, CAChicago, ILMinneapolis, MNWhite Plains, NYStockton, CATracy, CAStockton, CARichmond, IndianaHayward, CABurley, IDCaldwell, IDHarburn, IDColumbus, OHChicago, ILBattle Creek, MIChicago, ILSan, CAClifton, NJLaselle, Que, CanadaChicago, ILMontreal, CanadaEast Hanover, NJPortland, ORMontreal, CanadaAubigny, FranceGorinchen, HollandHamburgBattle Creek, MICincinnati, OHWalla Walla, WAJanesville, WI

Distribution

Cannery & Distribution CenterCorporate HeadquartersW/H and DistributionGrainCannerySugar RefineryCanneryFruit ProcessorProcessing & Distribution CenterSugar RefineryW/H and DistributionDry Case Goods & DistributionDistribution

Food Processing & DistributionCannery & Distribution CenterCanneryCannery & Distribution CenterPet FoodProcessing & Distribution CenterPotato ProcessorPotato ProcessorPotato ProcessorCannery (Pet Food)Food ProcessorFood Processing & DistributionDistributionDistributionDistributionDistributionCannery & ProcessorFlour MillFood ProcessorW/H and DistributionW/H and DistributionW/H and DistributionW/H and DistributionW/H and DistributionDry Case GoodsMill and Distribution CenterCanneryDistribution

94

Northern Fruit Co.

FOOD PROCESSING CONTINUED

Stokely-Van CampStokely-Van CampStokely-USATri-Valley GrowersT.J. LiptonBristol-MeyersHunt-Wesson FoodsNestle GluckskleeNestleOgilvy Mills

FOOD FRESH

Alturus PackingBordo Citrus ProductsCitrus WorldDiamond FruitFlorida Citrus Packers Assoc.Gracewood FruitGulf & WesternHHLAIndian River ExchangeLakeland PackingLake Hamilton CitrusLykes PascoOrange Co.Seald Sweet Sales Packing Co.SunkistTexas Citrus & Vegetable

FOOD DISTRIBUTION CENTERS

Alford’s Cold StorageBig BearCalifornia Canners & GrowersCarnationDistribution Centers, Inc.Empire FreezerFernandes Supermarkets, Inc.Geneva Cold StorageGiant FoodsHolman TransferInland Underground WarehousesJewell T CompanyKrogerLivingstonNational Distribution WarehousePenn-Central

Fairmont, MNOakland, CAPoynette, WISacramento, CAEnglewood Cliffs, NJHill Side, NJFullerton, CANeustadt, GermanyYorkMontreal, Canada

Connersville, FL

Lake Wales, FLHood River, ORLakeland, FLVero Beach, FLFellsmere, FLHamburg, GermanyVero Beach. FLLakeland, FLLake Hamilton, FLDade City, FLLake Hamilton, FLTampa, FLOntario, CAHarlingen, TX

Dallas, TXColumbus, OHMilipitas, CAStockton, CACincinnati, OHSyracuse, NYNorton, MSDarien, WILandover, MDPortland, ORKansas City, MOMelrose Park, ILColumbus, OHLaval, Que. CanadaClearfield, UTColumbus, OH

CanneryCanneryCanneryW/H and DistributionDry Case GoodsDry GoodsFood Processing & DistributionW/H and DistributionDistributionFlour Mill

Growers and ShippersFruit (Citrus)

Fruit (Citrus)Fruit (Apples, Peaches, Pears)Food - FreshFruit (Citrus)Fruit (Citrus)W/H & DistributionFruit (Citrus)Fruit (Citrus)Fruit (Citrus)Fruit (Citrus) & Distribution CenterFood - FreshFood - FreshFrozen and Fresh Fruit ProcessorsFood - Fresh

WarehouseWarehouseWarehouseWarehouse (Public)

Distribution CenterW/H & DistributionFood Distribution CenterWarehouse (Public)

Food Distribution CenterWarehouseWarehouse W/H & DistributionWarehouse (Public)Warehouse (Public)

95

Northern Fruit Co.

FOOD DISTRIBUTIONCENTERS CONTINUED

Perlman RocqueRJR FoodsSLW WarehousingSafewaySafewayServmarkTerminal Ice & Cold StorageVan de Water RaymondWinn Dixie

FROZEN FOOD

Adams Packing Association, Inc.B & W Frozen Foods, Inc.Birdseye (General Foods)Citrus World, Inc.General FoodsHolly Hill Fruit ProductsLamb-WestonLibby, McNeill & LibbyMcLain’sMartin-BrowerMartin-BrowerMorton Frozen FoodOre-IdaPik’s Rite, Inc.Plymouth Citrus Products

STONE, CLAY, GLASS

BaroidIndustrial MineralsRiverside Cement

BEVERAGE

Allied DistilleriesBarton GuestierBelgium PackhoedChauteaventChivis & GlenlivetCoorsCoorsDrambuieHeinekenHoughMumms

Lamont, ILWinston-Salem, NCLachine, Que. CanadaRichmond, CAPortland, ORSt. Bruno, Que. CanadaWoodburn, ORLaval, Que. Canada

Auburndale, FLBradenton, FLWoodburn, ORLake Wales, FLWinterhaven, FLDavenport, FLPortland, ORDarien, WI & Ocala, FL

DesPlaines, ILHalthorpe, MDCrozet, VAPortland, OR

Plymouth, FL

New Orleans, LAFlorin, CACrestmore, CA

Dumbarton, ScotlandBlanqefort, FranceAntwerp, BelgiumBonnieries, FrancePaisley, ScotlandTustin, CAGolden, COEdinburghDen Bosch, HollandColoradoReims, France

Distribution CenterWarehouseW/H & DistributionWarehouseW/H & DistributionW/H & DistributionCold Storage WarehouseW/H & Distribution

Fresh Food Processors

Fresh Food Processors

Clay Mill (Bagged)Clay Mill (Bagged)Cement Plant (Bagged)

Distillery W/H & DistributionWineryContainer Unloading-SpiritsWineryDistillery W/H & DistributionDistributorBreweryDistillery W/H & DistributionBreweryDistributionWinery

96

Northern Fruit Co.

BEVERAGE CONTINUED

Oregon Liquor ControlQuebec Liquor BoardR.D.S.SeagramsSeagramsUnited DistilleryUnited DistilleryWM GrantWhite Horse

AGRICULTURAL PRODUCTS

Albers Mills Co.Cities ServicesCitrus WorldLake Hamilton CitrusLykes Pasco

PAPER PRODUCTS

American TissueGaylord ContainerMead CorporationPackaging Corp.StoneWaterway TerminalWeyerhaeuser

BUILDING MATERIALS

CloroxExcell Dist.G.E. Lamp DivisionHome-DepotJohns-ManvilleRaymond ShakeWeyerhaeuser (Shake Division)

ELECTRONICS

AppleAppleAppleAppleAppleAppleBosch/BlaupunktCannon

Portland, ORMontreal, CanadaCaliforniaLawrenceburg, INLaSelle, Que. CanadaKilmarnock, ScotlandValleyfield, Que. CanadaBellshill, ScotlandGlasgow, Scotland

Portland, ORTampa, FLLake Wales, FLLake Hamilton, FLDade City, FL

Tomahawk, WICarol Stream, ILCincinnati, OHTomahawk, WISalinas, CAPortland, ORColton, CANew Orleans, LA

Houston, TXHouston, TXBridgeport, CTAll LocationsWaterville, OHRaymond, WARaymond, WA

Itasca, ILLes Ulis, FranceApeldoorn, HollandMunchen, GermanyHemel Hempst.CorkHildesheim, GermanyAmsterdam, Holland

Distribution WarehouseW/H & DistributionDistributionDistilleryDistillery W/H & DistributionDistillery W/H & DistributionDistillery W/H & DistributionDistillery W/H & DistributionDistillery W/H & Distribution

Feed Mill (Bagged)Chem Fertilizer Plant (Bagged)Citrus Pulp (Cattle Feed)Citrus Pulp (Cattle Feed)Citrus PUlp (Cattle Feed)

Pulp Bales*Corrugating PlantCorrugating PlantPulp Bales*Corrugating PlantPulp Bales*Corrugating PlantCorrugating Plant

*using pushers only

W/H & DistributionW/H & DistributionBuilding MaterialsInsulationInsulationShake & Shingle MillShake & Shingle Mill

W/H & DistributionW/H & DistributionW/H & DistributionW/H & DistributionW/H & DistributionW/H & DistributionMfg. W/H & DistributionW/H & Distribution

97

Article 8 (cont.)

ELECTRONICS CONTINUED

CannonCannon EuropeCompaqHewlett PackardHewlett PackardPanasonicPanasonicPhillipsSharpSonySonyXeroxYamaha

RETAIL

Home DepotWalMart

CHEMICAL

Ciba GeigyHoechstHoechstKodakKodakProcter & Gamble

OTHER

AmwayBecton DickinsonMeyer Corp.Nippon DensoQuaker State Oil

Crawley, U.K.AmstelveenGorkumCorvallis, ORAmersfootCardit, South Wales, U.K.HamburgEidhoven, HollandWrexham, U.K.South Wales, U.K.Koln, Germany

Rellingen, Germany

Manchester, U.K.Frankfurt, GermanyOberhausen, GermanyStuttgartHemel Hems, U.K.Manchester, U.K.

Denver, CO.Temse, BelgiumBenicia, CAWeesp, Holland

W/H & DistributionMfg. W/H & DistributionMfg. W/H & DistributionMfg. W/H & DistributionMfg. W/H & DistributionMfg. W/H & DistributionMfg. W/H & DistributionMfg. W/H & DistributionMfg. W/H & DistributionMfg. W/H & DistributionMfg. W/H & Distribution

Mfg. W/H & Distribution

DistributionProduction & ShippingProduction & ShippingDistributionDistributionDistribution

DistributionPharmaceuticalImportingAuto Parts

cP.O. Box 20187

Portland, Oregon 97220800 CASCADE (227-2233)

www.cascorp.com

98

Converting to Slipsheets

PUSH/PULL &SLIPSHEET HANDLING MANUAL

SLIPSHEETING –FROM TEAM TO REALITY

Apple ComputersWhy did we decide on the slip-sheet handling process?

Solution to receiving problem■ Project champion (defined

team responsibilities)

Unit load handling benefitsvs. standard wood pallet

■ Variety of carton sizes■ Shipping equivalent of 250

truck loads of pallets a year

Why was slipsheeting thecorrect solution?

Labor requirements - reduced

Warehouse utilization/scheduling - improved

Material expenses - reduced

Transportation costs - reduced

Implementation strategyGlobal logistics

■ Apple distribution network

Dedicated team approacha must

■ Slipsheet vendor qualification■ Equipment vendor

qualification■ OEM vendors conversion■ Distribution warehouse

support■ Manufacturing participation

& support

■ Carrier conversion■ Distributor director shipment

supportCommunications

Concept, process, benefits,objectives with:

■ Distribution center■ Packaging engineering■ Manufacturing■ OEM procurement■ Transportation■ Vendors & distributors

Commitment – ongoing processsupport required

Packaging engineering■ Product changes■ New products

New vendorsQuality control program &support requests

Implementation plan outline:Select core team members(inside & outside)

■ Project champion (definedteam responsibilities)

■ Committed team slipsheetvendor

■ Committed team equipment(attachment) vendor

Develop slipsheet specification■ Custom slipsheet for

electronics

Develop unit load configura-tions & specifications

Vendor win-win strategy■ Trail shipments

Phased program—implementation process

■ Communications(project overview)

■ Equipment procurement (specifications)

■ Trial shipments (video’s)■ Start-up training and

checkout (certify)■ Follow-up support & quality

control participation

Long term planning■ Two-year project from idea to

100% implementation

Training (start-up & follow-up)

Customer satisfaction(follow-up communications)

Potential problems toimplement slipsheeting

Process issues and concerns

Converting truck carriers

Can we succeed 100% FG orhave some hand stacking?

Number of locations to convert(extensive effort)■ Company global buy – in

and supportRequired commitment fromall groups

99

Converting to Slipsheets

Benefits

Cost savings for apple andvendors

■ Transportation■ Material■ Labor■ Reduced product damage■ Shorter receiving turn around

or time to market■ Better cube utilization of

warehouse facilities■ Better space utilization of

warehouse facilities■ Cleaner and safer warehouse

environment■ Have also implemented

incoming vendor materials

Summary

The first electronics corporationto implement the slipsheetprocess on a global basis

The results have exceeded ourexpectations

100

Slipsheeting – Making It A SuccessFor Suppliers

Key to success:Win – Win

Pallets

Container Pattern Using Pallets

Total Cartons Per Container: 1,012

Example:Part Number: 12345Description: Computer ProductVendor: Overseas Supplier

Container Size: 474" x 92" x 93.7"(12040mm x 2337mm x 2380mm)

Unit Load Size: 48.3" x 44.7" x 36.4"(1227mm x 818mm x 925mm)

Unit Load: 9 per level & 4 levels high

Carton Size: 16.1" x 14.9" x 9.1"(409mm x 379mm x 230mm)

Number of Unit Loads: 44

Number of Cartons Per Unit Load: 36


Carton Weight: 15 lbs.

Total Container Weight: 23,760 lbs.

Utilized Width:89.4"

Top View End View

Utilized Height:83.5"

Load Fill

101



Slipsheets

Container Pattern Using Slipsheets

Example:Part Number: 12345Description: Computer ProductVendor: Overseas Supplier


Unit Load Size: 44.7" x 32.2" x 45.5"(1135mm x 818mm x 1156mm)








Utilized Width:89.4"

Top View End View

Utilized Height:91"

Load Fill

102



Utilized Width:90"

Top View End ViewBefore Hand Stacking


Slipsheet

"Old Box" Method

Container Pattern Using “Old Box” Method

Example:Part Number: 87926Description: Another Computer ProductVendor: Another Far East Supplier


Unit Load Size: 45" x 40" x 39.5"(1143mm x 1016mm x 1003mm)



Number of Unit Loads with 5 Layers: 22


Number of Unit Loads with 6 Layers: 22


Total Number of Unitized Cartons: 968

Number of Cartons Hand Stacked: 44




103



Utilized Width:90"

Top View End ViewBefore Hand Stacking


Slipsheet

"New Box" Method

Container Pattern Using “New Box” Method

Example:Part Number: 87926Description: Another Computer ProductVendor: Another Far East Supplier







Total Number of Unitized Cartons: 1,056





104



Utilized Width:91"

Top View End View

Utilized Height:89"

"Hand Stack" Method

Container Pattern Using “The Hand Stack” Method

Example:Part Number: 67890Description: Another Computer ProductVendor: Overseas Supplier #2



Total Cartons Per Container: 756


105



Utilized Width:91"

Top View End View

Utilized Height:89"

Slipsheets

Container Pattern Using Slipsheets

Example:Part Number: 67890Description: Another Computer ProductVendor: Overseas Supplier #2







Total Number of Unitized Cartons: 756


Total Cartons Per Container: 756



106

Slipsheeting – Making It A SuccessFor SuppliersHow are suppliers approachedwith regards to slipsheeting?

Present method of shipping andwhy we want to change

How it is going to affect suppliers

Advantages to both suppliers and Apple

“Preferred Vendor”

Assistance in implementation

Emphasis on “Win – Win”

Why are suppliers important?

Accountable for configuration of product

Responsible for ensuring load issafe for transit

Responsible for proper utilizationof container/trailer

Slipsheets

107

Apple's Distribution

DistributionEngineering

U.S. Distribution

Manufacturing& OEM’s

InternationalDistribution

Charlotte

Boston

Sunnyvale Chicago

Dallas

U.S. Staging

Far East OEM’s

Cork

Singapore

Fremont Canada

Australia

Paris

Zeist

InternationalStaging

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108

SLIPSHEET SPECIFICATIONS

Slipsheet Specifications

SLIPSHEETSPECIFICATION

Quality of Slipsheet—4 Key Issues

Strength of the sheet■ Cardboard Perception■ WW Transportation■ Quality 4 Ply Sheet

Length of Pull Tab■ 6" Tab Story■ Scores Improve Tab Roll

Unit Load Design■ Tray to Secure Unit Load■ Stretch Wrap Spec■ Many Product Sizes

Vendor Qualification■ Vendor Process■ Tooling Costs■ Order Quantities■ Support and Delivery

Goal—To Provide The BestQuality Slipsheet in theElectronic Industry

MATERIALS HANDLING SYMPOSIUM

MARCH 1, 1989Santa Clara, CA

Tray Tab

Tray TabPull Tab Scores

Pull TabLocking Corner

109

SLIPSHEET WITH LOCK-IN CORNER


AppleComputer, Inc.

Unit Load

Lock-inCorner

Pull Tab

Pull Tab

110


LockingCorner

Datum

Z

W

L

Z B

A

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P� �

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LockingCorner

Datum

Z

P

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L

P

S

Z

A

B

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SINGLE SCOREDSLIPSHEET

Dimensioning:Z-L-P x Z-W-P

Figure 1

SOLID FIBER SLIPSHEET

MULTI SCOREDSLIPSHEET

Dimensioning:Z-L-S-S-S-P x Z-W-S-S-S-P

Figure 2

LEGEND

L = Smallest LengthW = Smallest WidthZ = Fixed 101.6 mm

[4.00] TabS = MIN. 25.4 mm

[1.00] ScoringP = MIN. 50.8 mm

[2.00] Tab Apple

Computer, Inc.

111


SOLID FIBER SLIPSHEETSPECIFICATIONSSheets are to be constructedfrom 100% � Virgin FourdrinierKraft Linerboard, Laminatedwith waterproof adhesive. Mustmeet minimum specificationslisted below.

Caliper: 1.17mm � .076mm[0.046 � 0.003]

Ply: 4-Ply, 18.9 kg[42.0 lbs.]

Average Tensile Strength:MD 428 PSI[30.2 kg/cm2],CD 178 PSI[12.5 kg/cm2]

Coating: Top side of sheets to bestriped with Anti-SkidCoating to cover at least50% of the sheet.

Scoring: See slipsheet drawing.

1. Tray Tabs (Z)Scored at 101.6 mcm [4.00]from edge of slipsheet. Deepscore in grain direction.Perforated score on the crossgrain tab in increments of 6.4mm [.25] perforation per25.4 mm [1.00] length.

2. Pull Tabs (P)Additional scoring on Pull Taballows for unit load dimensionincrease up to 50.8 mm [2.00]in each of the overall lengthand width directions while stillaccommodating a minimum of50.8 mm [2.00] pull tab forhandling the unit load.

■ Scores must be a minimum of25.4 mm [1.00] apart.

■ Pull tabs (P) are not toexceed 101.6 mm [4.00].

■ Minimum pull tab exposed forhandling the load is 50.8 mm[2.00].

■ All scores to be parallel with-in allowable tolerance of �1.5 mm [.06] non-cumulativeand measured from thedatums -A- and -B-.

Dimensioning:Unit load length and width isspecified by a user accordingto unit load dimensions(Figure 1). The pattern isused to specify the exactdimensions of each requiredSlipsheet. The dimensions ofthe tray tabs and pull tabs arelisted in the scoring section ofthis document. Refer toFigures 1 and 2 for the fol-lowing dimensioning notation.

(Figure 1)Z-L-P x Z-W-P

(Figure 2)Z-L-S-S-S-P x Z-W-S-S-S-P

Locking Corner:Designed to provide a per-manent lock of the tray tabsat a 90° angle. (See Figure 1and 2)

Corners:All corners, other than thelocking corner, are cut in a101.6 mm [400] radius withthe centers located 101.6 mm[4.00] from each corner onthe length & width scores.

Printing: PrintAPPLE COMPUTER, INC. Size L x W in minimum of19.1 mm [.75] letters downthe center of the top side ofthe sheet.

Example:APPLE COMPUTER, INC.SIZE 12119.1 mm x1066.8mm [48.0 x 42.00]

AppleComputer, Inc.

112


Notes:1. All “Z” tabs (Fig 1)

measure 101.6 [4.0].

2. All “P” tabs (Fig 1)measure 50.8 [2.0].

3. Tensile strengths shown areminimum.

AppleComputer, Inc.

942-1201 1 1 40.5 N/A N/A N/A X 29.5 N/A N/A N/A

942-1202 2 1 40 1 N/A N/A X 34 N/A N/A N/A

942-1203 3 1 43 1 N/A N/A X 39.5 N/A N/A N/A

942-1204 4 1 43 1 1 N/A X 40 2.5 N/A N/A

942-1205 5 1 45 N/A N/A N/A X 34 N/A N/A N/A

942-1206 6 2 45 2 1 N/A X 39 1 2 N/A

942-1207 7 1 45 N/A N/A N/A X 45 N/A N/A N/A

942-1208 8 1 46 N/A N/A N/A X 31 N/A N/A N/A

942-1209 9 2 46 1.5 N/A N/A X 39 1.5 1 N/A

942-1210 10 1 47 N/A N/A N/A X 44.5 N/A N/A N/A

942-1211 11 1 48 1 1 1 X 42 1 1 N/A

942-1212 12 1 49 N/A N/A N/A X 37 N/A N/A N/A

942-1213 13 1 49 N/A N/A N/A X 38 N/A N/A N/A

942-1214 14 1 50.5 3.5 N/A N/A X 35.5 1 N/A N/A

942-1215 15 1 50.5 N/A N/A N/A X 44 N/A N/A N/A

942-1216 16 1 51.5 N/A N/A N/A X 43.5 N/A N/A N/A

942-1217 17 1 52 N/A N/A N/A X 39 N/A N/A N/A

942-1218 18 1 54 N/A N/A N/A X 37 N/A N/A N/A

Part No.Vendor

Size FigureDimensions (Inches)

L S S S W S S S

113

Converting Do's & Don'ts

DO’S & DON’TS OFCONVERTING TOSLIPSHEET HANDLING

By Lloyd C. DickManager, Manufacturing Services

Mead Paperboard Products

INTRODUCTION

C ompanies contemplating achange to slipsheets must under-stand that it is a materials han-dling system which must be prop-erly planned and executed toinsure success and to obtain max-imum benefits. They should alsounderstand that there is neitherreason for anyone to fail in hisattempt to adopt the system nor isthere reason for anyone to re-invent the wheel. Much has beenaccomplished during the past ten

years, or so, in a great variety ofindustries, which has proven thatthe slipsheet system can workextremely well if properlydesigned and installed.

We suggest that anyone planning touse slipsheets begin thinking of theslipsheet as a new materials han-dling system. Various parts of thesystem must work together proper-ly for success. These most impor-tant ingredients can be summarizedas follows:

1. A proper unit load for the product.

2. A proper slipsheet for the unitload, product and distributionsystem conditions (a wide varietyis available).

3. Proper equipment and adequatetraining in its use.

4. Proper understanding of theslipsheet, how it is supposed tofunction and how it must prop-erly match the material han-dling equipment to be used.

5. Proper consideration for thereceiver’s unloading andstorage facilities.

6. Dedication to the new system bykey individuals within theorganization covering planning,purchasing, marketing andoperations. Ideally, one individ-ual within the company willassume responsibility for thesystem’s success.

Check List For Establishing Proper Slipsheet Unit Load Handling Operation

“THE SLIPSHEET DO’S”A. Is the slipsheet correct for the unit load?

1. Size, Length-Width Stacking surface same size as unit load—never larger

2. Unit Load WeightLight Weight Cases Corrugated or light caliper solid fiberHeavy Weight Cases Heavy caliper solid fiber required to avoid tab tearing

3. Stiffness ForBagged Products Heavy caliper solid fiber for stiffness so attachment can grasp tab properly.

4. Moisture Exposure Coating of outer liners with moisture barrier material and high sizing toresist moisture penetration that would weaken tab area.

5. Tensile Strength If only one use planned, sufficient tensile strength for 6 to 10 pulls withouttab tearing. If sheet to be returned and reused, much greater tensilestrength required.

6. Tabs Required 3" or 4" deep tab for each direction or pull. If side and end tab used, mustrelieve intersecting corner so tabs can fold independently of each other.May be need to consider “extra” tabs for use with stretch film to stabilizeload in transit.

114


“THE SLIPSHEET DO’S”(cont.)

B. Has the unit load been prepared properly?

1. Overall Unit Load Size Determine size to best fit cube of shipping container (trailer, car, etc.)consistent with capacities of shipping and receiving material handlingequipment. This will minimize freight costs.

2. Stacking Pattern Determine stacking patterns for various case sizes to best fit overallunit load size selected. Turn and interlock cases on alternate layers forimproved load stability.

3. Placement of Production Keep score lines and tabs completely free of product. Keep first cases Slipsheet 1/4" to 1/2" away from score lines. This will permit tabs to be folded

up against unit load in transit and will minimize tab tearing.

4. Load Stabilization Needs Bottom cases must be prevented from shifting onto tab areas in transit.Use either palletizing adhesive on slipsheet or wrap unit load withstretch film, trapping tab in 90° up position.

5. Breaking The Slipsheet Tab Pre-breaking the tab on the score line will facilitate necessary up foldwhen loading and will minimize tab tearing when tab edges are hit byhandling equipment.

C. Have push/pull operators been trained properly?

1. Approaching The Unit Load

2. Picking Up The Unit Load

3. Decking The Unit Load

4. Undecking The Unit Load

5. Positioning Unit Load On Warehousing Pallet

6. Removing Unit Load From Warehousing Pallet

7. Placing Unit Load In Shipping Container

8. Removing Unit Load From Shipping Container

9. Maintenance of Push/Pull Equipment

D. Has the loading operation been performed properly?(Loading should always be performed with the receiver in mind)

1. Leave front tab readily Push tab into 90° up position against each unit load. This will restrict accessible and in good movement of bottom cases onto tab area in transit. Tape front tabs in upcondition for receiver position at trailer tailgate or before positioning bulkhead in railcar.

2. Maintain straight Obtain straight alignment on dock against backstop prior to loading vertical alignment of if equipment has capacity to lift two unit loads. Use sideshifter to obtaintired unit loads good vertical alignment. Use dunnage to fill void areas, as necessary.

115


“THE SLIPSHEET DON’TS”1. Don’t place cases of product on the slipsheet tab area or score line. This will prevent tab from folding

properly and cause tearing.

2. Don’t push tab so it “crumples”. A bent or crumpled tab can damage other unit loads and tear whenmoving the unit load, unloading, etc.

3. Don’t approach load at an angle. Approach unit loads squarely. Damage can occur to cases if a cornerof the push/pull plate makes contact first.

4. Don’t slam the push/pull faceplate into the unit load when squaring cases during loading. Hidden dam-age may result.

5. Don’t attempt to pull a unit load from a stack with the mast tilted back. The platens may be pulled intocontact with the unit load underneath the one being moved, causing damage.

6. Don’t leave unit loads stacked so that one is out of line vertically with the other or damage will result.Use the sideshift to place one unit load squarely on top of another.

7. Don’t use reverse gear to drive the truck from under the unit load or damage will result. Always useproper technique when pushing a unit load off platens.

8. Don’t leave slipsheet tabs in positions where they can be easily damaged. Loose tabs can jam or getcaught causing damage to cases during the following unit load moves. Tabs can be taped against unitloads to avoid such damage.

E. Will the slipsheet perform at all levels in the distribution cycle?

1. Receiver unloading Each receiver must have proper size and capacity equipment.equipment Sideshift capability is recommended to avoid product damage.

2. Receiver driver training Each receiver Push/Pull operator must also receive trainingoutlined in “C” above.

3. Receiver warehousing If wood warehousing pallets are used, pallets must be properlyfacilities constructed and sized to avoid damage to slipsheets and product. Fork

tines can damage slipsheet tabs unless proper equipment and methodsare used.

116


RECOMMENDEDGUIDELINES TO FOLLOWFOR SUCCESSFULPUSH/PULL TEST

Load Preparation■ First load—pick a stable

product easily handled.■ Weight—approximately 1500

to 2000 lbs.■ Interlock cases.■ 40" x 48" load base –

40" to 50" high.■ Stabilize top of load with band

of tape, stretch wrap, etc.■ Dunnage—If load is suscepti-

ble to movement in transit,consider dunnage for last twounit loads over truck/trailerwheels to prevent movement.

Slipsheet■ Solid fiber, strong heavy duty

slipsheet that can compensatefor initial inexperienced lifttruck driver.

■ Test the use of break awayglue between the load baseand the slipsheet to determineif the glue is needed to preventthe load from walking or mov-ing on the slipsheet in transit.

Lift truck■ Capacity—Without push/pull

attachment, at least 1200 lbs.more than the maximum loadweight to be carried.

■ Mast—Free lift 50" to stackand de-stack inside truck/trailer. Overall mast loweredheight 83” or less to enterthrough truck/trailer doorway.

Lift truck driver training■ Cascade 1/2 inch VHS video

available to illustrate use ofthe push/pull.

■ Driver training brochure(Owner’s & OperatorsGuide) illustrating importantdriver techniques.

■ Obtain sample slipsheet toenable drivers to practice withslipsheets prior to initial ship-ment of loads.

■ Select one or two proficientdrivers that are anxious tooperate new equipment.

■ Have driver practice pickingup floor load plus stackingand de-stacking second tieredloads.

■ If possible, the first slipsheetload should be sent to distri-bution center in time toallow the driver an opportu-nity to become familiar withslipsheet handling prior tosending observers to watchtest loads.

■ Ship test loads to DistributionCenter of both difficult andeasy to handle load.

■ Have observers watch load.

Cascade Sales AidsCascade video tapes are available for purchase at a cost of $40.00 netprice. Prices include postage and handling. Format standard 1/2" VHS.

E-Series Push/Pull Features Video #209207

Push/Pull Driver Training Video #677557

Palletless Handling Program Video #204320• Palletless Handling • Slipsheet Handling at Northern Fruit• Receivers Your Day • Slipsheet Handling at Bristol Meyers

117

Home Depot

HOME DEPOT’SCONVERSION SPURSINTEREST IN SLIPSHEETS

the WERC sheetWarehousing Education

& Research Council

When Home Depot talks, vendorslisten. And that’s what happened lastyear when Home Depot, Inc.,announced that it was convertingfrom pallets to slipsheets and wouldnot accept palletized freight afterJanuary 1, 1995.

Slipsheets–which for a time seemedto be the stepchildren of the materialhandling world–were dismissed bycompanies in most industries formany years.

Even before Home Depot’s announce-ment, however, use of slipsheets hadbegun to spread beyond the traditionalfood industry application. Slipsheetsare now being used to ship electronics(including personal computersand laser printers), chemicals,pharmaceuticals, liquor, and textilessuch as apparel, linens and hosiery,says Cynthia Holloway, marketingmanager for slipsheet manufacturerLydall, Inc., Richmond, VA.

Substantially greater slipsheet usemay be in the cards for many WERCmembers. Holloway reports that hercompany has seen strong interestfrom one major retailer carryingsuch a broad spectrum of productsthat its conversion to slipsheetscould have an even greater impactthan Home Depot’s. If this retailerrequires vendors to ship on slip-sheets, Holloway predicts, “a wholegroup of people who have neverbeen exposed to slipsheets before”might find themselves required toconvert to their use.

THE HOME DEPOT STORY

Converting to slipsheets is a majorundertaking that requires carefulplanning and preparation, as illus-trated by Home Depot’s experience.

Citing potential cost savings andenvironmental benefits of slipsheets,Home Depot introduced its programin stages, beginning with its Northeaststores in 1993. In May of 1994, thecompany announced to its vendors:

■ That it was expanding use ofslipsheets to its other regions;

■ That all stores would beequipped to receive producton slipsheets beginningAugust 1;

■ That vendors were encouragedto test slipsheets for productshipped to its stores viaregional LTL, truckload or pri-vate carriage trucks;

■ That five months later vendorswould be required to slipsheetall product shipped in thatmanner.

Recognizing that converting to pallet-less handling would be a major

change, the company provided plentyof support and training for its vendors,including one-day seminars and aslipsheet hotline that’s been in placesince August.

“We wanted to help our vendorscome on line,” recalls Home Depot’sTravis Szwast, who mans theCompany’s slipsheet hotline inAtlanta, “not just force our policy onthem.” He fields questions with ven-dors who might be having problemswith slipsheets or have questionssuch as where to get equipment ordifferent types of slipsheets.

As a result, vendors are buying intothe program, Szwast says. “We’vehad a very good response.” Close to300 vendors fully support the slip-sheet program, he says.

The retailer also worked closely withits carriers. For example, RoadwayExpress and Home Depot testedshipments in the less-than-truckload(LTL) environment for a year and ahalf. “We began with relatively smallscale tests,” notes Bob Obee.Roadway’s vice president of opera-tions, planning and engineering,

Although converting from pallets to slipsheets is an involved process, many companiesmay be forced to make this transition in the future.

118

Home Depot

“putting some 50 shipments throughthe system.”

Using ideas generated from analysisof results, Roadway and Home Depottested specific proposals and differ-ent slipsheets by running some 70shipments–perhaps 100 unit loads–through the network. Roadway care-fully tracked the shipments, photo-graphing them on both ends of theshipments and feeding data back toHome Depot, whose personnel inmany cases was on-site.

The tests revealed important infor-mation. “We were able to confirmthat there was a definite need,”Obee says, for a sturdier slipsheetthan typically used in the truckload(TL) environment where slipsheetshave traditionally been used. Thisfinding held true for both plastic andcorrugated slipsheets.

Home Depot and Roadway workedclosely with slipsheet manufacturers,developing designs potentially moresuitable for the LTL environment. Asuccessful design involved addingtwo tabs, one on each side of theslipsheet. This change resulted ininterlocking corners on the slip-sheet. When the freight and slipsheetare shrink wrapped, Obee says, theslipsheet acts as a tray for the freight,making for a more stable load. Andthe additional two tabs make it pos-sible to approach the slipsheet fromany side with a push/pull attachment.

TRAINING IS KEY

Converting from pallets to slipsheetsrequires a major change in workmethods, materials and equipment.Roadway, for example, is introducingtwo types of equipment: at lightervolume facilities, wide platens whichslip over forklift tines; at heaviervolume facilities, hydraulic push/pull attachments.

Slipsheets 101

Slipsheets are available in threematerials: corrugated, fiberboard,and plastic. Corrugated slipsheetsare made by sandwiching corrugated(fluted) material between a top andbottom liner. Fiberboard slipsheetsare made of three plies of kraftliner board laminated together.

The material used in corrugatedand fiberboard slipsheets weakenswhen it gets wet. Plastic slipsheets,the most expensive, are frequentlyused in moisture-laden or wetenvironments. While Home Depotis encouraging use of plastic slip-sheets by its vendors, fiberboardslipsheets are used most widelythroughout industry.

Many slipsheets are custom-designed,according to Randy Wise, NationalSales Manager for Shippers PaperProducts Company, Lancaster, Pa. Avariety of slipsheet designs andweights are available from slipsheetmanufacturers, depending upon thesize of the footprint of the load, andthe number of tabs or lips required.

Slipsheets are described in terms oftheir thickness, or “caliper”. Calipermeasures one-thousands of an inch,or a “point”. A .060 caliper boardmay be referred to as a 60 pointboard.

Thickness of the sheet does not cor-relate necessarily with the strengthof a sheet. Tensile strength, ratherthan thickness, is the primary deter-minant of which slipsheet is rightfor your application, Wise says.Some users specify recycledmaterial, but the use of recycledpaper instead of first run Kraftpaper, for example, can result in

loss of tensile strength as therecycled fibers get chopped intoshorter and shorter pieces.

Reusability of slipsheets depends onthe situation and the durability ofthe slipsheet. A toy manufacturerthat uses and reuses slipsheets forinterplant shipment of productspecifies a fairly substantial slip-sheet, with a specially reinforcedtab. “Most users without a closedloop distribution system don’t reuseslipsheets,” explains Rick Diermeier,sales and marketing manager forMenasha Corporation.

“When selecting a slipsheet for aspecific application, several factorsmust be taken into consideration,”Diermeier says: “number of timesthe unitized load is handled bypush/pull equipment; unit loadweight, composition and stability;moisture exposure; operatorexperience; receiver requirements;case size, product characteristicsand packaging or type of container.”

“Specifying a slipsheet that’s tooflimsy and weak is a false economy.Test a variety of slipsheets to deter-mine performance,” advises DianaTwede, assistant professor in theSchool of Packaging, Michigan StateUniversity, reporting that companieslike Apple Computer have the schooltest slipsheets and develop perform-ance specifications based on tensilestrength and coefficient of friction.

Some loads may have a tendency toslide off a slipsheet. This can beavoided by using an adhesive,shrink or stretch-wrapping the slip-sheet to the product, or using afour-sided slipsheet.

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Home Depot

Training employees in the use of thenew equipment is critical to thesuccess of the slipsheet program. Atraining program was developed forRoadway, Home Depot, and vendors’employees. The program is presentedin two half-hour modules.

Safety is a key component in thetraining program, which combinesvideo and written materials.Operators are shown how toinstall and remove equipmentsafely, how to prepare the surfaceto ensure that it’s level, and howto handle freight properly.

Included in the training is a clearexplanation of why Home Depot andRoadway are converting to slip-sheets. Explaining the whys andwherefores of the change, saysRoadway training and developmentspecialist Patti Powell, helpedemployees–and Home Depot ven-dors–understand the environmentaland financial benefits of doing so.Employees have bought into thechange, rather than resisted it. Now,Powell says, employees are enthusi-astic about the conversion.

WEIGH THE TRADE-OFFS

“Slipsheets are a load-base alterna-tive that should be considered whenadopting a system to handle unitcosts,” according to David Spencer,Corporate Manager MaterialsHandling, Jefferson-Smurfit Co., aslipsheet user and manufacturerlocated in Alton, IL.

“They’re not for everyone, but theyoffer a growing opportunity to savemoney and space and ultimatelyhave a more cost-effective end userproduct. Companies should evaluatewhether use of slipsheets,” he con-tinues, “can make their productmore competitive for the end user,”

But, he says, companies should alsobe sure they’re fully aware of therequirements necessary to imple-ment a slipsheet system successfully.

Converting to slipsheets, like anysystem-wide change, requires care-ful consideration and analysis ofbenefits and trade-offs. Here’s around-up of information to help youdo so.

■ Slipsheets cost less than pal-lets, ranging from under adollar to $5 each. Pallets maycost $6-9 each.

■ Many slipsheets can be usedjust once; plastic slipsheetsmay be reused a limited number of times. Pallets canbe reused many times. So calculate per-trip cost as wellas cost per item.

■ Slipsheets are maintenance-free, without the problems ofextruding nails or brokenboards.

■ Use of slipsheets frees up asmuch as 10% additionalspace in a truck trailer orcontainer. “If you’re shippinga light density product,”observes Don Allison, “Thatsaving goes straight to thebottom line. And 10% of afreight bill is a huge number.”Allison heads up ComputerizedPackaging Consultants inGreenwood, Ontario.

The space saving achievedthrough use of slipsheets ismeaningless, however, if trailers weigh out before theycube out.

■ Slipsheets create less wasteand are easier to disposeof–they can be included inyour corrugated recycling

program. Pallets are recyclable,but sortation and storage canbe an issue.

■ If slipsheets get wet, they losetheir strength. Wet corrugatedslipsheets in particular willtear immediately. “This can bemitigated with special coating,”notes consultant Robert B.Silverman, partner, Gross &Associates, Woodbridge, N.J.,“but then the price of the slip-sheet goes up, and it stillwon’t have the same strengthas the pallet.”

■ Slipsheets require far lessroom than pallets to store,but, unlike pallets, can’t bestored outside.

■ Slipsheets don’t store in palletracks easily. “You have todeck the pallet racks with atype of decking that the slip-sheet won’t get caught on,”Silverman says.

■ Use of slipsheets limits theheight to which you can floor-stack product. “It’s tough toaccess a slipsheet 16 feet inthe air from the ground,”Silverman explains. “A palletgives the lift truck operator afour inch hole to aim for withthe fork. With a slipsheet,there’s no margin for error,and the required depth per-ception is tough to master.”

■ Slipsheets may not be appro-priate for products that requireair circulation, compared topallets, which create a fourinch gap underneath the load.

■ Use of slipsheets requires spe-cial push/pull lift truck attach-ments or equipment that’smore costly than the fork lift

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Home Depot

truck. Many distribution cen-ters currently don’t have suchattachments or equipment.

■ Customers and/or vendorsmay not have the equipmentrequired to handle slipsheets,thus may be forced to purchasesuch equipment, handstackproduct or unload it by hand.

■ Lift truck operators must betrained in using push/pullequipment, which requires “a higher skill level for theoperator,” Silverman says,“More training is required;more experience is requiredfor proficiency.” Operationsthat use temporary labor orhave high turnover may incurexcessive training costs.

■ While productivity with slip-sheets over time can get closeto what it is with pallets, theconsultant continues, it doesn’tequal productivity that’sachievable with pallets becauseof the greater number of han-dling steps involved.

■ Slipsheets may require wideraisles in storage. “The lifttruck must turn a full 90degrees to access a slipsheet,”Silverman explains, comparedto the 60-70 degree turnrequired to access pallets.

ARE SLIPSHEETSRIGHT FOR YOU?When considering the use of slip-sheets in your operation, carefullyevaluate the cost of storage andhandling to ensure that the use ofslipsheets doesn’t actually add morecost because of increased handling.Consider the amount of handlingyou do internally, advises consultantSilverman, versus the number of unit

loads that you ship and receive.

In addition to material and spacesavings, calculate the cost of storageand handling equipment, training,the difference in productivity, andany effect the conversion might haveon your operation (such as widen-ing the aisles or adding deck rack-ing). Factor in what effect the use ofslipsheets might have on your trans-portation rates, if any. Then examineyour organization’s payback criteriato determine whether it’s worthmaking a change to part or all ofyour operation.

“Slipsheets aren’t necessarily an all-or-nothing proposition,” explainsSilverman. “They might be applicableto a certain portion of your opera-tion.” Some companies’ plants, forexample, ship to distribution centerson slipsheets to increase trailer utilization, while the DC makes out-bound shipments on pallets.

Also consider the impact a conver-sion might have on vendor andcustomer relations. “System-wideimplications are important,”explains Diana Twede, AssistantProfessor in the School of Packagingat Michigan State University. “If yourconversion to slipsheets means that100 of your customers will have topurchase special materials handlingequipment, the cost will probablyoutweigh the benefits.”

“Shippers and consignee’s gain separate economic benefits from aslipsheet system,” Twede continues.“Cost and benefit have to be sharedequitably among both parties in therelationship.”

Be prepared to take full advantageof the benefits offered by slipsheets.“Space is dollars,” notes packagingconsultant Don Allison, so if you doswitch to slipsheets, be sure to re-

design your packages so that youcan take advantage of the additionalspace. Allison redesigned pretzelpackages for Snyders of Hanoverwhen it converted. The result: morethan $350,000 savings annually.

Certainly slipsheets are not right forevery operation or for every product.But if your product is compatiblewith slipsheets and you haven’t con-sidered them lately, industry expertssuggest you revisit the topic.

“Slipsheets fall in between a palletized load and handstackedload,” explains Bob Silverman.“Slipsheeted loads allow you toapproach the container/trailer utilization of a handstacked load,while approaching the productivityof a palletized load. In the right situations, slipsheets can help youcome close to achieving the best ofeach of those options.”

For More Information■ Home Depot’s Slipsheet

Hotline: 404-801-5710 (canbe used by all companies, notjust Home Depot vendors).

■ “Fiberboard SlipsheetManual” by American PaperInstitute, available fromMenasha Corporation (414-751-1511) and other slip-sheet manufacturers anddistributors.

■ National Wooden Pallet andContainer Association, (703-527-7667). RequestTechnical InformationSheet–Slipsheets or Pallets?

“Reproduced with permissionof the Warehousing Educationand Research Council”

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CORRUGATED/SOLID FIBER SLIPSHEET SUPPLIERS

International Paper Longview Fibre Company Lydall SouthernContainer Division P.O. Box 666 Products Division6400 Poplar Ave. Longview, WA 98632 3021 Vernon RoadMemphis, TN 38197 Phone: (360) 425-1550 Richmond, VA 23228Phone: (901) 763-5996 Fax: (503) 244-1192 Phone: (804) 266-9611Fax: (901) 763-6047 Fax: (804) 266-3875

Rock-Tenn Company Smurfit Stone Shippers Paper Products983 South Marr Road Container Corporation 1203 North Main st.,Columbus, IN 47201 401 Alton Street P.O. Box 69Phone: (812) 378-0308 Phone: (618) 463-6312 Mt. Pleasant, TN 38474Fax: (812) 378-7331 Fax: (618) 463-6395 Phone: (800) 933-7731

Fax: (931) 379-7735

PLASTIC SLIPSHEET SUPPLIERS

Baron Enterprises PSS Eaglebrook Plastics PlasTech Inc.4950 Colorado Blvd. 2600 West Roosevelt Rd. 70 South Eaton CourtDenver, CO 80216 Chicago, IL 60608 Lakewood, CO 80226Phone: (303) 316-6800 or Phone: (888) 511-1200 Phone: (303) 202-0852Phone: (800) 354-7707 Fax: (312) 491-2501 Fax: (303) 202-0454Fax: (303) 316-6888

Repsco USA Polymer2950 Arkins Court 9295 Baythorne Dr.Denver, CO 80216 Houston, TX 77041Phone: (303) 294-0364 or Phone: (713) 690-8742Phone: (888) REPSCO Fax: (713) 690-50251 (888) 737-7261Fax: (303) 337-9600


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How Push/Pulls Work

A. B.

1. Extend the pusher plate so that the slipsheet lip fits into thegripper channel opening

2. Retract the pusher plate.The gripper bar will automaticallyclamp the slipsheet lip.

3. Move forward slowly as the load is being pulled onto the platens. 4. Raise the carriage about one inch. Slowly tilt the mast to avertical position as you scoop up the load.

C.

Types of Push/PullsA. Sideshifting standard on all

carriage mount push/pulls.B. Hydraulically adjustable platens.

• For applications requiring extensivepallet handling.

• Allows driver to adjust the platenspread from his seat.

C. Sideshifting platens.• Works like basic sideshift except the

frame doesn’t move.• For narrow or restricted applications.• 8” sideshift capacity.

D. Load Push• Does not have gripper mechanism to

pull slipsheet.• For loads that are “scooped” onto

the platens.

E. Mark 55 push/pull (pg. 125) • Platens open for slipsheet handling and

close for pallet handling.F. Sheet Sav.® (pg. 126)

• Allows the driver to retain the slipsheetwhen the load is pushed off.

G. Inverta Push™ (pg. 127)• Return your pallets in-house, and

reduce your total pallet inventory.

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35E & 45E Push/Pulls

35E & 45E CarriageMount Push/Pulls All E-Series carriage mountpush/pulls are equipped withCascade’s SIDESHIFTING feature(see A.) for unbeatable maneuver-ability and with Q.D. hooks forconvenience. The 35E model israted for maximum load capacityof 3,500 and 45E for 4,500 lbs.Other differences include:

The 35E is designed for shortwheel-based, counter-balancedtrucks in the 2,500 to 4,500 lbs.capacity range. The small truck 35Ecombination provides maximum netload handling capacity, short overalllength and excellent maneuverabili-ty. It is ideal for truck trailer andrail car work, as well as for generalslipsheet warehousing applications.

The 45E is a heavy duty push/pull,well suited for double load stackingapplications, as well as for rail carloading and unloading.

OPTIONS■ Quick-Change Hydraulic

Couplers■ Hydraulic Flow Control Valve■ Extended Height and

Width Faceplates■ Faceplate Stop Group■ Attachment Mounted Solenoid

Adaption Group■ Optional Platen Sizes■ Forks and Multiple Fork Groups

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1. Position forks under platens

QFM™ Push/Pull

Mounts directly onthe lift truck’s forks in one minute.APPLICATIONS

QFM Push/Pulls are ideal forapplications requiring quick andconvenient removal and installa-tion of a push/pull attachment.The rugged Cascade QFM can beinstalled or removed in less thanone minute and does not requireremoval of the lift truck forks.Typical applications are thoserequiring an attachment for slip-sheets on an intermittent orirregular basis.

2. Connect quick-change hydraulic couplers

3. Engage lower hooks

(Quick Fork Mount)

FEATURES

Protects both products andslipsheets from damage

High production slipsheet handling capabilities

Strength and durability to workin demanding applications

OPTIONS■ Quick-change hydraulic couplers■ Special faceplate heights

and widths■ Faceplate stop group■ Truck mounted solenoid

adaption group■ Class III mounting■ Various platen sizes■ Extended opening ranges

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Mark 55 Push/Pull

Mark 55 Push/Pulloffers flexibility tohandle slipsheetedand palletized productPlatens open for slipsheet handling and close for pallet handling.

APPLICATIONSThe Cascade Mark 55 Push/Pull isthe solution for operations that musthandle both slipsheeted and pal-letized product. Hydraulically posi-tionable outer platens are easilyopened for conventional slipsheethandling, and closed to allow pallethandling. In addition, the Mark 55Push/Pull allows four-way handlingof the popular Mark 55 block pallet.

FEATURES■ Hydraulically adjustable

outer platens■ Sideshifting capability standard■ Class II mounting standard■ High visibility pantograph,

gripper jaw and faceplate■ 4˚ tilting faceplate■ Protected hydraulics■ “Cushion” cylinders

OPTIONS■ 3,500 and 4,500 lb. capacity

models available■ Quick-Change hydraulic couplers■ Hydraulic flow control valve■ Extended height and width

faceplates■ Faceplate stop group■ Optional platen sizes■ Truck-mounted solenoid

adaption group■ Hydraulic load cushion■ Quick Disconnect and Class III

mountings

1. Platens spread

2. Close platens for 2-way handling of traditionalGMA pallets or 4-way handling of Mark 55block pallets.

3. Open platens for conventional slipsheet handling

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Sheet-Sav™ Push/Pull

Slip sheet handlingwith the added abilityto retain and reuseyour slip sheets.

APPLICATIONSUse the Cascade Sheet-Sav™Push/Pull to keep your slip sheetsin house. This is a popular attach-ment for manufacturers who han-dle product on slip sheets withintheir operation and who transferproduct without a slip sheet onto apallet, into a container, or onto aflatbed truck. Popular for baggedcement, bagged seed and grain,packaged food, dairy products,fruit and produce and corrugatedbox blank handling.

FEATURESHigh production slipsheet handling capabilities■ High visibility pantograph,

gripper jaw and faceplate■ Adjustable platens■ 4° tilting faceplate■ Chamfered platen corners and grip-

per jaw design protects the slipsheet■ QFM models: Frame mounts

between forks (20” wide) forminimum effective thickness(lost load)

Strength and durability in demanding applications

Save your slip sheets using aSheet-SavTM Push/Pull.

Grip slipsheet and pullload onto platens.Transport load todesired location.

Press Sheet-Sav™ knobbutton and activate lever

to raise foot.

Press Sheet-Sav™ knob buttonand activate lever to lower foot.

Push load off platenswhile retaining slipsheet.

➀ ➁

➃ Press Sheet-Sav™ knob but-ton and activate lever to raisefoot, then remove sheet.

➄➂

OPTIONS■ Quick-change hydraulic couplers■ Hydraulic flow control valve■ Extended height and width faceplates■ Extended push strokes■ Faceplate stop group■ Optional platen sizes■ Forks and multiple fork groups■ Class III mounting (45E only)

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Inverta Push™

Retain your pallets in-house, and reduce yourtotal pallet inventory.APPLICATIONSCascade’s Inverta Push may be usedin nearly every operation that shipsunit loads of bags or cartons, suchas fertilizer, grain, cement, mail,sugar, canned goods, boxed goods,glass and plastic.

Retrieving your pallets with anInverta PushThe Inverta Push enables you towarehouse your products on in-house, ‘captive’ pallets. For shipping,the Inverta Push places the load on aslip-sheet, customer pallet or direct-ly on the transit vehicle floor, thenretrieves your pallet. Your palletsneed never leave the warehouse.

Retaining your expensive pal-lets in-house eliminates theneed to dead-head pallets afterunloading at the destination.The receiver has no return costs topay and you can reduce your totalpallet inventory.

The Inverta Push consists of twoopposing sets of forks for clamp-ing, an automatically sequencedstabilizer arm on the side withforks, an integral sideshifter, arotator to invert or rotate theload and a push plate for push-offload deposit.

How it Works➀ Bottom forks are inserted in

pallet. Load is clamped againstupper forks. Side stabilizerengages load to secure it for rotation.

➁ As truck moves to load-outpoint, Inverta Push turns 180°so pallet is on top of load.Slipsheet or customer pallet (ifused) is now on bottom.

➂ Forks lift pallet off load.Operator pushes off and backsaway simultaneously.

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