Sustainapack

These 0.015" thick disposable trays are designed to fit perfectly in a standard 12"x12"x6" cardboard box. Each tray is designed to hold 12 parts, and every 12"x12"x6" box can hold 4 trays (48 parts/box.) Assuming a standard pallet size of 40"x40" and 3 layers of 9 boxes, each pallet can hold 1,296 parts. Obviously the box quantity is much less than desired 200 +/-10% parts/box; however, this design takes into account ergonomics by replacing heavy or oddly shaped packaging with easy to carry, light weight, standard sized boxes. These boxes can then be easily stacked on to a pallet for ease of transportation and shipping.

They trays are designed to be stackable, as to optimize storage space when not in use. Another feature of these trays is they can be rotated 90 degrees from the tray directly below it to allow the trays to rest on each other, not the parts. This allows the trays to support themselves while the parts remain securely inside and greatly reduces any potential part damage during shipping. In addition the trays themselves have numerous ribs and other strengthens features to increase packaging robustness, while still allowing easy packing and unpacking of the parts.

Finally these trays are designed to be manufactured from regrouped thermoplastic left over from the parts themselves, and all variations of switches provided are accommodated by this design.