CHALLENGE

A leading Fortune Global 500 e-commerce retailer faced excessive noise from molded plastic containers on conveyor systems in their distribution centers, violating OSHA noise level standards. This required costly hearing protection measures for employees.

INITIAL SOLUTION & ISSUES
Switching to fiberboard containers reduced noise but introduced problems:
■ Short Lifespan: Containers lasted only 3-4 months, increasing replacements.
■ Operational Disruptions: Shedding fibers disrupted barcode scanners and conveyor efficiency.

SOLUTION & IMPLEMENTATION
Through collaboration with a trusted reseller and the end customer, MDI developed a custom corrugated plastic solution designed to:
■ Reduce noise on conveyor systems.
■ Withstand harsh distribution center conditions for over a year.

Initial Design
■ Diagonal corrugation deflected noise effectively but led to totes flying off conveyors at high-speed corners.

Final Adjustment
■ Adding hardboard to the bottom increased weight, stabilized the totes, and ensured smooth conveyor operation.

BENEFITS

  1. Noise Reduction: Diagonal corrugation design in the plastic totes effectively deflected noise, addressing OSHA’s noise level concerns.
  2. Conveyor Functionality: Adding hardboard to the bottom of the totes increased weight and stability, preventing them from flying off at high-speed corners and reducing conveyor disruptions.
  3. Product Lifespan: The durable corrugated plastic totes lasted over a year, significantly outlasting the fiberboard & cardboard containers and reducing fiber shedding.

CONCLUSION
This solution highlights the value of collaboration between MDI, resellers, and end customers. Together, they addressed complex challenges, delivering a durable, noise-reducing solution that improved operational efficiency and compliance in high-demand distribution environments.

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