Importance of Packaging in Supply Chain Management

 

Sankar Rajeev

(Retd) Former Professor Business Studies, KL University, DCSMAT, WBCM, KKWIEER.

*Corresponding Author E-mail: 731.s.rajeev@gmail.com

 

ABSTRACT:

Establishment of efficient linkages and making a strong and transparent supply chain is the essence of modern day manufacturing. The inventory costs and transportation costs constitute a large proportion of the overall costs. In a competitive world efficiency of manufacturing would be to reduce the cost of manufacturing to increase profit rather than increase selling price to increase the profit. It is true that customer would be displeased with a product in case it is damaged or tampered. So for reduced inventory, transportation cost and safety and security of the product transported packaging is an important aspect. With the emphasis on Green supply chain efforts are being made to reduce the dependency on packaging materials, more so an effort to go in for reusable packaging materials. The proposed research work has the aim of analyzing the importance of packaging in supply chain management. Review of literature indicates that the aspect of packaging is crucial in the field of supply chain management. Studies carried out on the financial aspects of supply chain management have brought out factors such as lack of attention given to packaging of products. A descriptive research methodology is adopted. In the past such a correlation has not been attempted realistically, thus it was found that a study would be enriching, useful and interesting. The findings will give an insight on to the relevance of practicable methods to undertake innovation in the field of packaging not only at the industry level but also at global operations level and may serve as input in improving profitability, ensuring efficiency in business methods and support further research on the subject.

 

KEYWORDS: Supply chain management, Packaging, Profitability, Customer satisfaction, Global operations.

 

 


INTRODUCTION:

Supply chain logistic operations include inventory management, transportation modes and services provided, transportation operations economics, pricing and administration, warehousing activities, packaging, material handling and operational integration. Inventory management is an important activity in supply chain logistics operations. Stocking of inventory costs money and shortage of inventory creates non delivery of products to customers resulting in reducing customer satisfaction. A good inventory policy creates an acceptable inventory performance which in itself is bound by service level and average inventory.

 

 

Inventory carrying cost is the expenses related to maintaining inventory which is a product of average inventory value that is taken at the time of inventory purchase or standard manufacturing cost (not selling price) with annual inventory carrying cost.  Financial factors utilized to arrive at inventory carrying cost which is represented in percentage are capital invested at a specified rate, local taxes on inventory held in warehouses, insurance cost, and deterioration during product storage, cost associated with storage facilities. The FOB deliberation and inclusion of transportation cost at purchase price and product cost is also necessary. Inventory management implements inventory policy. Parameters included are inventory carrying cost, order points and quantities. Product characteristics like fragility can influence the cost. Classification does not identify the movement cost. It includes fixed costs also. Economic benefits accrue when existence of a warehouse reduces overall cost of logistics. Service benefits include spot stocking, line stocking and value added services. It is here that packaging becomes a factor to reckon with to improve the supply chain activities.

 

Economic value is efficiency of product or service creation resulting in high quality at low cost. Economic value strategizes procurement and manufacturing, market value on distribution strategy and relevancy value on supply chain strategy we can consider packaging as an equally important factor. Supply chain planning system and related information system seeks to integrate information and coordinate overall logistics and supply chain activities including activities involving other firms.  Supply chain applications include demand planning, requirements planning and transportation planning. Requirements planning use evaluative methods to trade off the cost of production which includes packaging, inventory, storage and transportation. In transportation planning sensitivity of goods, proneness to damage and packaging assumes importance. Information-directed material handling systems uses RF wireless (Wi-Fi) and light directed operations. Supply chain planning system and related information system seeks to integrate information and coordinate overall logistics and supply chain activities while coordinating activities involving other firms.  Benefits of supply chain planning are responsiveness to changes, rapid commitments to customer, enhanced resource utilization and limiting customer surprises. 

 

All these aspects lead on to the point that in supply chain management packaging is an important function. Why is it so? Packaging is undertaken to identify and protect products during transportation. In this article we would rather concentrate on designing, evaluating and producing packaging to add value to supply chain. Tin plate packaging was generally used until the packaging industry developed paper based packaging. Probably in the early twentieth century plastic arrived on the scene for packaging. It is documented that by 2003 packaging contributed to 2% of GDP in developed countries and by 2019 the packaging market was over $300 billion. It is generally focused on marketing and logistics. Packaging can be categorized as primary such as the material which initially envelops the product, secondary which is used to prevent pilferage or group products with primary packaging and transit packaging which is essentially used for bulk carriage. For damage protection, products are grouped into cartons, bins or barrels. Containers used to group individual products are called master cartons, which when combined are referred to as unitization. Master cartons should be large enough to provide handling economies of scale but at the same time movable without mechanical assistance. Reusing vendor cartons is no more practiced and has been replaced by using standard master carton that can be reused three times. It facilitates order picking and materials handling which uses computer process to ensure that carton is packed to the maximum practical cube utilization and permit continuous conveyor movement from point of warehouse order selection to truck loading. It may be possible that master carton standardization may not be complete; during such cases it is necessary to make an assortment of compatible units. Arriving at a satisfactory packaging involves providing protection with allowable damage. General causes identified of product damage are vibration, impact, puncture and compression. While packaging simulated testing is conducted to arrive at allowable protection for the product on being transported, considering the mode of transportation we have to understand the importance of packaging in supply chain management. Apart from the primary function of protecting the product it serves the purpose of leveraging in a competitive world. It also felicitates in communication of the parameters of the product to attract the customers and keep the competitors away. Packaging also provides economy of space and with that there is saving in warehouse and transportation cost. Attractiveness of packaging puts in value addition in another way which is increasing the life of the product. An illustrated packaging with instructions for the users and features of the product allows the customer to understand and helps in decision making.   

 

For packaging to contribute to the value chain the basic requirements are waste and source reduction. Waste reduction is by analyzing the optimum requirement before considering packaging and source reduction can be undertaken by obviating the tendency to undertake over packaging. It has been identified that packaging is one of the major promoters of the product in a competitive business environment. Definitely some amount of luster has been taken away by the online markets but still it plays an important role. Packaging in a supply chain environment should have linkages with marketing, logistics, production and environment. Packaging plays a key role in marketing of a product. Facilitating material flow by ease of handling has been found not only to reduce material handling time but also safety of the content or product. While interacting with a warehouse manager it has been identified that packaging improves traceability of an item.   

 

LITERATURE REVIEW:

Send Points, (2017), Flexible Packaging, International Kindle Paper white brings out a new phenomenon; flexible packaging. The author states that when we adopt a packaging technique where the shape can be changed at ease the technique is called flexible packaging. It is presumptuous to state that over the period of time flexible packaging has assumed importance and large number of western countries have moved that way supported by a number of associations. Materials generally used for flexible packaging are plastic film, paper, aluminum foil, fabric etc. At times combination of these materials are also used. Flexible packaging is commonly used in food and pharmacy industry. Rather inquisitive, adventurous and progressive; this book invites suggestions on flexible packaging. Through an excellent showcase of design works, the book will lead us into the lesser-known world of flexible packaging. Chris Huang, (2016), Fashion Packing Now, International Kindle Paper white; the book includes current, up-to-date knowledge components for designers, brand managers, retail managers, and educators in the fields of product and graphic design. Informative to larger extent the book goes on to include pictorial representations of packaging in respect of clothing packaging. It further goes on to include sketches and conceptual designs. In a competitive world of fashion apparels manufacturers are resorting to various innovative packaging designs. These are able to lure the customers by distinctive, conspicuous and decipherable designs for apparel packaging.  In many cases packaging has become a marketing tool expressing itself in to various competitive lines of messaging. These images can further augment branding with eye catching designs of packaging.  So in a way these flexible trendy and fashionable packaging can improve the spoken reputation of the company and its products by a visual representation of what can be expected of the product. To increase the level of understanding live case studies of reputed company’s in assorted brands of products and product lines have been included.  This book will be a source of inspiration for design aficionados, advertising and merchandise managers, students, brand and retail managers, and educators in the product design and graphic design fields. Ryan Goff, (2017), Even More Schedule for Sale, Author house, generally covers the aspect of construction productivity in the field of industrial projects. Main thrust area is advanced work packaging. It goes on to elaborate aspects of workface planning. In advanced work planning the thrust is on forming the team or organizing the team for the primary objective. This would be better done by value streaming the deliverables based on the needs of the industry. So it levels to the point of evolving graduated response to the acceptable industrial practices in the area of construction. Eventually workface planning develops into advanced work packaging. 

 

Sasi Pankaj, Kadam SU, Misra NN, (2011), Trends in Food Packaging, VDM Verlag brings out that ever since globalization and liberalization set its foot prints on marketing and global economic practices, food packaging has assumed importance. Primary aim was to provide protection and prevent from deterioration over longer periods of storage. However, with the change in consumer demands and technological innovations, food packaging has evidenced a great deal of extensions to its original functions and new packaging materials are constantly being added to the existing list. An attempt has been made to provide a detailed and thorough market insight, in terms of the prevailing food packaging materials for the diverse range of foods flooding the global market. Unlike other products food packaging is a sensitive issue. In the case of food packaging, products dictate the material which can be used for the purpose. It suffices to say that unlike generic products food packaging is a trendy subject which needs careful analysis. Packaging Technology and Engineering: Pharmaceutical, Medical and Food Applications, (2020) Wiley is a book which covers the packaging engineering and technology.  In that way it starts with the scientific aspects of packaging materials of various kinds. As the book progresses there are other fields such as universal issues and application aspects which are included.  The coverage is exhaustive so in addition to being a reference book for anyone in the field of packaging it has industrial applications.  After beginning with an overview of the history of the topic, it then offers chapters on the methods of obtaining raw materials, the chemistry of polymeric and non-polymeric packaging materials.

 

METHODOLOGY:

The research design adopted is explanatory method. Such a method has been taken on considering the fact that we are focusing on the aspects of packaging as it relates to the Supply chain management (SCM). Here the effort is aimed at exploring and explaining the aspects of packaging in the context of SCM. The goal is to understand the importance of packaging and identifying innovative methods which can benefit the customer and improve profitability by reducing the cost price. Even though an explanatory research is a pure research carried out with specific real world-application in mind, and as always to develop new knowledge for improving lives. Here, in this research we would often relate to real application in the industrial world. So in a way we would not be having a clear hypothesis, but tries identifying the impact of packaging in SCM. 

 

RESULTS:

Generally when a person considers packaging the scope limits to safety of the item. Probably it is with this aim that all courier companies, transportation companies, and e-commerce establishment looks at this function. Over the years it has been found that in addition to the task of protecting the product packaging can effectively serve many other purposes. I was going through an article on the flood relief carried out in New York many years back. One fine day the volunteer engaged in the support operation was in a dilemma, when he had only one packet of relief material to provide but seven people queued up for it. He probably had a restless night like many of us who were at times engaged in emergency relief. It was at that time he went into the study of the packaging of the three-day ration packed for each of the affected person. On his analysis it was found that there was large empty space (approximately 30% of the volume) in each of the package as a result of which packages were bigger than necessary. Further on he found that making the package of the required size resulted in transporting more number of packages in the vehicle provided for the purpose. So it leads us to the inseparable link between packaging and SCM. As transportation cost covers substantial portion of the overall cost of the product, it suffices to say that any saving in this area benefits overall SCM.

 

The next consideration is to see whether packaging can perform any additional task. It was tried out and found with reasonable success that a good packaging system can be a value addition to the product. The value addition can be by many ways, including branding of the product. An attractive packaging becomes signature for a good product. Customers while comparing two products of near equal quality may be lured towards a product with a better packaging. It would be quite appropriate at this stage to discern that attractive packaging with pictures of the product performs the task of advertising the product. Even though with the advent of internet and mobile platforms the customer can have preview of a product form the web, the features of the product as listed on the package becomes a hands-on reference to the customers in decision making. In high end products especially in FMCG or fashion apparels the trend is on fashion packing. By introducing various designs the manufactures can attract the customers to their products by bringing in a feeling of class.  So by the fashion packaging firms are moving the product to a higher level and creating a status consciousness. This way new set of customers are created for the products resulting in improved profitability. In addition to mandatory disclosures on the packaging, industries marketing food products indulge in providing technical information which creates health consciousness awareness. So a person with disposable income is lured into the product in comparison to a competitor’s product.

 

Flexible packaging is another concept and green SCM advocate’s use of reusable packaging materials. With the proliferation of market place and warehouse model of electronic SCM the load on packaging materials is quite high. Probably the realization that there is large dependency on forest produce for making packaging materials major companies are going in for flexible and reusable packaging to obviate over dependency of packaging materials. With the covid protocol and restrictions on movement, on line shopping was actively brought into the culture of customers. This in a way had a serious drawback in terms of packaging in the way of waste generation and cutting down of trees.  Identifying the impact of this fall out firms has now resorted to biodegradable, recyclable and edible packaging. In fact all these methods are innovative and environment friendly hence can be adopted. Out of these innovative methods the influence of edible packaging is more productive considering that in case the packaging for any product can be made with edible products such as post-consumer resins, bagasse, hemp and polylactic acid which can be consumed by live stock it would add to the resource creation methods being worked out by various countries. Digital printing and AI assisted packaging can drive to generate optimum methods of palletization and containerization in warehouse management system and transportation SCM.

 

Some of the other technology friendly innovations in the field of packaging are digital packaging, active packaging, 3 D printing and Nano technology.  In SCM the packaging needs to be smart, interconnected and active. How is this done? It is generally done by elementary methods like QR codes and RFID tags or say, Kanban. However the thought process should be on more technological methods since incorporation of IE 4.0 by making use of augmented reality and internet of things. In food industry the requirement of active packaging with food spoilage detection sensors can be of great help.

 

DISCUSSION:

As all logistical operations are affected by packaging it is necessary to analyze package utility and its impact on logistical productivity and efficiency. In this packaging design, unitization and information of transfer are key elements.  In addition to marketing utility, protection to the product while considering packaging attention is also drawn to logistical efficiency. Reducing the package size with due consideration for the essential qualitative requirements like removing air pockets, reducing box size is another step.  Cubes out and weigh out are quantitative parameters usually worked on even though it represents added challenge for online operations of customer demand. Grouping of master cartons to physical units for material handling to increase handling and transport efficiency is called unitization or containerization.  Unit loads have numerous advantages such as; minimizing unloading time and congestion at the destination, material handling, reducing manual loading and unloading by 80% time, verification, inventory positioning ready for order selection rapidly, and reduction in in-transit damage.

 

There can be rigid and flexible containers. Rigid containers are sealed containers which provide protection and facilitate handling. It is commonly used in airlines. Returnable containers are used to distribute products in integrated environments where security is a key issue. Deposit systems are used for beverages, kegs and pallets. On the other hand flexible containers do not protect products by complete enclosure. In this master cartons are stacked on pallets or slip sheets. Slip sheet is similar to pallet but for the fact that they are made of plastic or cardboard, hence light weight and cost effective. As a matter of convenience, larger a platform it is more efficient for material handling, however size determination is based on load, compatibility with handling and transport equipment and standardized industry practice.  Tiering master cartons can be as a block, brick, row, or pinwheel. When cartons are of equal dimension block pattern is used, otherwise brick, row or pinwheel. Pallet exchange is an aspect which needs control and supervision.

 

Information transfer of packaging functionality is necessary to provide content identification, tracking and handling instructions. Information which considered is manufacturer details, product identification, container type, count, UPC, EPC. These are communicated using bar code or RFID technology. Hence high visibility packaging is recommended except for high value products. Logistical productivity has been considerably improved by material handling process which can be mechanized, semi automated, automated and information directed.  It is one of the important logistical activities in supply chain which happens throughout and has been greatly influenced by human resources, specialized equipments and space.  There are principles like standardized equipments, maximum continuous production flow, maximum utilization, gravity flow and minimum dead weight to payload. Mechanized systems include lift trucks, rider trucks, towlines, tractor trailers, conveyors, and carousels which consist of several bins in series mounted on an oval rack or track. Automatic guided equipments rely on optical, magnetic, or wireless guidance system, automated sortation using combination of conveyors that reduces labour and increase speed and accuracy, robots which has the ability to program functionality and decision logic to direct handling process and live racks are examples of semi-automated systems. The automated storage and retrieval system has the storage racks, storage and retrieval equipment, input-output system, and control system. The storage racks are vertical steel storage structures in which the storage and retrieval units travels up and down the aisle storing and selecting the product. Storage and retrieval equipment is a combined lift truck and pallet holder built into a movable crane and helps in reaching the desired storage location rapidly. Input-output system moves loads to and from the rack area, and the control system is akin to an automated order selection system which also handles inventory control and stock rotation. 

 

In a typical manufacturing plant, product automatically flows as unit loads into high-rise storage area by power conveyor, when it arrives at the assigned storage bin area moves it to the planned storage location, thereafter based on the orders received control system directs retrieval of specified unit loads. It is pilferage free, damage free handling with high accuracy but loses flexibility.  Information-directed material handling systems uses RF wireless (Wi-Fi) and light directed operations. Wi-Fi assisted systems use lift trucks and real time information interchange which are designed to achieve flexibility and utilization. Process of dedicating lift trucks to continuous assignments is called truck interleaving. Pick-to-light is a carousel system where order selectors pick designated items into cartons or conveyors from lighted carousel locations or storage bins. Light tree in front of each pick stations indicate the number of items to be picked from each station. A variation in this is put-to-light where order selector places product in lighted containers, indicating which customers should receive a specified product. In material handling e-fulfillment is a relatively new concept which introduce large number of small orders, wide range of products, hence people intensive, and increased customer expectations. Warehouses do have environmental concerns, being labour intensive they are prone to accidents, and owing to handling less volume due to reverse logistics. High performance material handling is the key to warehouse productivity because of the labour hours devoted for it, introduction of new technologies, later entry of automated system and lack of prominence at higher echelons of management.

 

Operational integration is centered on economic value, market value and relevancy value. Economic value is efficiency of product or service creation resulting in high quality at low cost. Market value relates to the projection of a mix of products at the opportune time and convenient place. Relevancy value means right products and services by customizing value added services. These three when combined requires total integration of overall business process resulting in integrative management value proposition. System concept is the total integration of components necessary for achieving stated objectives. System analysis is applied to logistics to create a whole integrated system which is more than the sum of individual parts of the function resulting in balanced performance between functions in search for overall results. This when considered from process perspective the goal is balanced between performance at functional area and supply chain. Compared to the traditional concept of long production runs and low procurement cost, the search is for total cost and customer impact on such practices. Here the focus is on interaction between components with each component attributing a special functionality necessary for achieving the objective. Economic value strategizes procurement and manufacturing, market value on distribution strategy and relevancy value on supply chain strategy. Interaction between components is key to system analysis with each component contributes a special functionality value. Performance of a total system is important hence individual components need not have the best design but what is more imperative is the integrated relationship between components that constitute the system.  Cross functional integration has been seen to achieve greater results than one deficient in coordinated performance. Logistical integration is as a result of responsiveness, variance reduction, control asset and turn velocity, containing transportation cost, quality and life cycle support. Along with logistical integration comes the requirement of enterprise integration. It starts off with integration of internal operations which is restricted by the existence of cross functional processes such as sand box or silo mentality, traditional measurement and reward system, leverage of inventory to facilitate functional performance, formatting of information on the basis of functional requirements, accountability to obviate infocratic structure and unwillingness to share knowledge. These are generally called the great divide which shows that the organizational condition where integration is partial and the absence of integration between the two types of external collaboration namely; supplier-manufacturer and manufacturer- customer (customer accommodation). Hence the external integration occurs in the absence of complete internal integration. Such a discontinuity is partly because of balance of power and absence of clear vision of internal processes in the senior managers. Therefore traditional organization cannot support a total integration and accentuates the great divide. So the organizational structure needs to be revisited. In logistics the great divide is to be removed by achieving a single guiding principle, supported by well-defined process, appropriate dimension, familiar estimation and development, and accommodating incentive system.  Separation of cross-organizational process serves to disrupt firms sustained supply chain operations, as also inability of participating partners to perform as promised.

 

Supply chain planning system and related information system seeks to integrate information, overall logistics and supply chain activities while coordinating activities involving other firms.  Effectiveness of this concept is driven by supply chain visibility on the location and status of supply chain inventory and resources, considering combined supply chain demand, capacity, material requirement and constraints, optimum resource utilization and amalgamation of data systems to enable decision making. This blending of all available resources is sales and operations planning (S&OP). It enables a coordinated approach for customer accommodation keeping in mind the resource constraints of the venture. Contrary to the contemporary integrated planning system, traditional outlook was to develop independent financial, sales and operational plans. Aim of supply chain operations is to increase the revenue by removing product variations, schedule distortions, and extended lead time to take advantage of economies of scale. As evident the aim being to take best advantage of manufacturing, transportation and economies of scale but unfortunately there is conflict in each of these objectives viewed independently. Hence it is necessary to systematically consider trade-offs and together create economies of scale by supporting forecasts worked out, product introduction, marketing tactics, and operating plans which can support the constraints of the firm with that of financial and customer obligations. Advance planning and scheduling system (APS) considers both spatial and temporary considerations like; suppliers, manufacturing plants, storage facilities, marketing chain, end customers, timing and scheduling. The last two are temporal considerations.  A product to reach customer a time period ‘a’ would mean that by time period ‘b’ it should be positioned at the distribution center for which shipment from plant should commence at period ‘c’. For this it can utilize uniform production or additional production using overtime or resort to outsourcing. Uniform production involves additional inventory costs, overtime would increase manufacturing costs and outsourcing costs. In APS the firm using linear combinations identifies relevant cost factor to achieve lowest possible total cost. Benefits of supply chain planning are responsiveness to changes, rapid commitments to customer, enhanced resource utilization and limiting customer surprises.  It can result in sustainable performance improvements.

 

Studies carried out reveal that in addition to facilitating smooth handling of products, packaging helps in increased product efficiency. Efficient consumer response is an important factor to be considered in marketing of products. It gives an impetus to increase the rapidity of inventory in a supply chain by creating linkages between producers, distributors, and customer relation management directed towards global fulfillment architecture and risk management. As packaging is considered in several parts of supply chain it is also connected with different levels of operations management. As business sectors are becoming more conscious of green supply chain management environmental aspects of packaging system plays an important role.   Whether it is brick and mortar or online stores more than the protection and service scape provided by the packaging it also generates a curiosity in the mind of the customer and impels to try out the product. As per certain scholars packaging is a multipurpose marketing tool. Another concept is on packaging logistics which involves the raw material to disposal of used packaging materials that brings in importance of creating synergy between packaging and logistics systems so as to bring in efficiency and effectiveness in supply chain. We may also find that packaging brings in a bond between the brand owner and the customer to generate a favourable impression on product quality.

 

CONCLUSION:

Over a period of time packaging has become a substantial contributor to business economy. Transportation alone costs up to 50% of the logistic costs and 10% of the price of the product.  Roughly about 11% of the cost of a product is factored as logistic costs. Out of this up to 34% of the cost assigned as logistic costs. [Are you spending too much on logistics; https://wwwedesk.com] Packaging can optimize this cost to a great extent. In general a company spends about 10-40% of the product’s retail price on packaging. As per the analysis carried out profitably this should come down to 3-7%. So each industry can plan product-wise methods to bring down the cost.

 

For damage protection products are grouped into cartons, bins or barrels. There are automated storage and retrieval system which has the storage racks, storage and retrieval equipment, input-output system, and control system. Information-directed material handling systems uses RF wireless (Wi-Fi) and light directed operations. System concept is the total integration of components necessary for achieving stated objectives.  Uniform production involves additional inventory costs, overtime would increase manufacturing costs and outsourcing costs. Benefits of supply chain planning are responsiveness to changes, rapid commitments to customer, enhanced resource utilization and limiting customer surprises. Packaging is also versatile marketing tool and logistics value addition, thus forms an important function of SCM.

 

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Received on 27.04.2023         Modified on 29.09.2023

Accepted on 26.12.2023      ©AandV Publications All right reserved

Asian Journal of Management. 2024;15(1):17-23.

DOI:  10.52711/2321-5763.2024.00003