packaging guide eng nov 2012 webb

8/20/2019 Packaging Guide Eng Nov 2012 WEBB

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Packaging

Guide


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WORKING GROUPThe FMCG Packaging Guide has been developed by one of the working groups appointed byECR Sweden and is represented by the following individuals:

Mario Balzano, Coop Sverige, Sofie Håkansson, Unilever, Marianne Köhler, Cloetta,Peter Jönsson, GS1 Sweden, Karolin Harsanji, GS1 Sweden, Jörgen Sjöberg, Bergendahls Food,Bert Rosenquist, Atria, Lars Hellström, SvDH, Charlotta Yrlid, Menigo, Thomas Henfeldt, Findus,Sampo Heikkinen, ICA Sweden, Mathias Dittrich, DLF, Magnus Selin, Procordia.

PROJECT MANAGERSMartin Hörberg, ICA Sweden and Anders Lindén, Axfood Sweden.

PRODUCTION MANAGERDaniela Veljanovska Pilipovic, ICA Advertising, e-mail [email protected].

DESIGN AND LAYOUTAnki Sandblom, ICA Advertising.

ILLUSTRATORThomas Franzén, ICA Advertising.

PUBLISHERECR Sweden, Box 1178, SE-111 91 Stockholm, SwedenPhone +46 (0)8 50 10 10 00, Fax +46 (0)8 50 10 10 01, e-mail [email protected], www.ecr.se.

ECR Sweden reserves the exclusive right to make changes to the text.All rights to reproduce this text for commercial use are reserved by ECR Sweden.


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DLF is an industry organisation for companiesproducing and selling goods to the FMCG andservice industries as well as to the restaurant andindustrial catering sector in Sweden. The missionof DLF is to communicate new knowledge, offerinspiring meeting places and conduct businessactivities that help develop the industry and makeit more efficient.www.dlf.se

SvDH is an association comprised of the followingretail companies: Axfood Sweden, ICA Sweden,Coop Sweden and Bergendahls Food. The pur-pose of this association is to address consumerconcerns. Furthermore, SvDH will coordinate andoptimise FMCG retailers’ efforts in developingareas of a competition-neutral nature. SvDHworks within three areas: Product Safety,Industrial Policy and Logistics.

www.dagligvaror.se

ECR (Efficient Consumer Response) Europe waslaunched at the end of the 1990s. At that time,new discoveries in the field of product supplydemonstrated that both retailers and supplierscould meet consumer needs better, faster andmore efficiently by co-operating on common,competition-neutral industry issues.

Additional factors that contributed to the ECRmovement gaining momentum were improve-ments in information technology, increasingcompetition, globalisation and the new larger

European market, which made it possible to movegoods and services more easily across nationalborders. Meanwhile, consumer demand devel-oped and began to focus on more factors thanever before, such as a wider selection, betteravailability, better quality, increased freshnessand improved product safety.

All these factors led to a fundamental change inindustry practices. The traditional division be-tween suppliers on one side and retailers on theother changed. ECR has contributed, and contin-ues to contribute, to removing unnecessary costs

in the supply chain. This increases the benefit to

consumers. The effects on the industry have beenconsiderable, and the ECR working method con-tinues to yield positive results.

ECR is about creating a holistic view of the entirevalue chain throughout the product path fromsuppliers, producers and retailers to the con-sumer. Generating benefits for the consumer is

the guiding principle of ECR. All work is aimed atincreasing the efficiency of the flow of goods andinformation and adding value for the consumer.

ECR is divided into two main areas: Demand andProduct Supply. The demand side deals with theintroduction of new products and the discovery ofmore efficient promotions. Examples of productsupply issues are demand-driven replenishment,including issues such as automated computer-based orders, and transportation optimisation.

ECR Europe was established in 1994. Two yearslater, ECR Sweden was established by DLF(Grocery Manufacturers of Sweden) and SvDH(Swedish Food and Beverage Retailers’Association).

The mission and objectives of ECR Sweden are:

• To spread knowledge about ECR to those in-volved in the Swedish FMCG (grocery) industry.

• To take the initiative and participate in businessactivities in ECR regions and to conduct investi-gations and projects when competition-neutralconditions exist.

• To conduct training sessions, seminars and con-ferences under the name ECR-FORUM acrossall organisational levels of companies in theindustry.

For more information, please seewww.ecr-europe.org.

Grocery Manufacturers ofSweden (DLF)

Swedish Food and BeverageRetailers Association (SvDH)


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PrefaceWhy is an FMCG Packaging Guide necessary?

The flow of goods and information from producer to consumer has becomeincreasingly complex, which affects those selling and supplying packagedproducts. Market players are faced with an increasing number of wishes anddemands, while simultaneously creating more demands of their own. The FMCG

Packaging Guide has been updated and adapted with a new modern design. Thisguide is intended to provide guidelines for the formulation and design of new

packaging or for the adjustment of existing packaging, and is supplemented withtips and advice to ensure packaging is able to withstand handling throughout theentire supply chain without any deterioration at the retail or consumer level.

The main objectives of the packaging:

• To protect and seal the products.

• To carry the brand name.

• To convey information to the consumer.

• To enhance the efficiency of logistics management with bar code labellingin accordance with the GS1 standard.

• To facilitate physical handling and delivery optimisation by following themodular system.

It is important, from both an economic and a durability perspective, thatpackaging is not only able to withstand handling in traditional warehousingoperations, but also that it is suitable for automated warehouses. The production

of goods, only to have them crushed in storage and during transportation due totheir packaging, is not only wasteful but also has an unnecessary impact on theenvironment. The Packaging Guide has already been adapted to ECR Europe’sBlue Book “Shelf-ready Packaging”.

The ECR 2012 edition is supplemented by Part II, Restaurants and IndustrialCatering and part III, Durable Packaging. Part III provides guidelines as to how

each package must be constructed or customised in order to prevent crushingduring transportation and warehouse handling. It includes guidelines on how to

test packaging in order to ensure it is able to withstand the physical environ-ment to which it will be exposed. It also includes guidelines on what is requiredof packaging to ensure that it can withstand handling in an automated processflow. In many respects, packaging in the industrial catering industry is similar topackaging in the FMCG industry. However, there are differences that must be

addressed in order to create a comprehensive common packaging guide. Aboveall, this concerns the appearance of orderable units and pallet construction, aswell as the fact that different names are used to refer to package recipients. TheFMCG industry regards the store, or possibly the consumer, as the final destina-tion, while the restaurant and industrial catering sector uses the term end-user(such as industrial kitchens, restaurants). This is described in part II.


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ContentsIntroduction

Holistic view and consumerfocus 6–9

Part I The FMCG Industry

Chapter 1 – item information 10–11What does item informationhave to do with packaging?

Chapter 2 – Consumer packaging 12–15Durable labelling and display

Chapter 3 – Outer packaging 16–21Shelf-ready packagingDisplay units and display palletsMulti-unit packagingLabelling

Chapter 4 – Pallets 22–29

Full-size, half-size, layer, mixed palletReplace, hire or invoice loading palletReturn, CHEP, EURO palletsApproved EURO palletsHow to build a pallet

Chapter 5 – The Modular System 30–33An efficient supply chain is based on modulesBasic modulesDimensions not included in The Modular SystemTower stack of small modulesSvenska Retursystem modules

Chapter 6 – Labelling 34–43GTIN and bar codesChoosing the numbering principleBar codesBar code label placementPallet label

Part II

Restaurants and industrial Catering 44–45

Part III

Durable packagingRequirements for outer packaging 46–51Common errors to avoids

Poor degree of fillingWeak perforation

Loose lids

Defective shrink-wrapping Edge of tray too low Substandard cardboard Unprotected products Poorly module-adaptation Outer packaging Glue leakage

How to test glue strength 52–53Glue leakage – the most common defect!What you needHow to measure the adhesive strengthof the glueQuality requirements for glued tabs

Packaging for automation 54–55RatioFlat bottom

Recommendations for pallets 56–63Full-size palletsCommon errors to avoid Not interlocking the pallet layers

Overhang on pallets Fragile goods prone to damage

Poor degree of pallet filling Unnecessary wrapping

Mixed, half-size palletsCommon errors to avoidPoor wrapping of half-size palletsPoor package construction

Recommendations for half-size palletsWrap the half-pallet with cardboard covers

Pallets for automationPlastic wrapping of pallet tunnelsPallet qualityOverhang and inclination of pallets

Glossary 64–67


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Introduction

Holistic viewand consumer focus

The 2012 Packaging Guide highlights the general flow of goods from producer to consumer,the information in this flow, and the types of packaging on which the system is based:

• Consumer packaging

• Outer packaging

• Multi-unit packaging

• Pallets

Taking a broad holistic approach is a key factor in the development of new packaging andthe review of existing packaging.

The customer must always be the focus. The customer is the same as the next link inthe logistics chain, and the last link in the chain is the consumer. At the same time, allrequirements and wishes from producer to final consumer must be weighed in and takeninto account in the decisions made.

Packaging should be rational and efficient for transportation and handling. It should beinformative and appealing in stores and it should be functional for the consumer. Packagingshould protect and preserve the product on its way from producer to consumer. For someproducts, it may also contribute to extended durability. Packaging is also an importantaid to handling that should work with pallets, in roller containers (roller cages, milk cages,rolling racks, etc) and on store shelves.

The function of packaging is to protect the productsand to facilitate handling from producer to store andon to the consumer. See Part III, Durable packaging.


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GuidelinesStandards for the flow of goods and information are published by ISO, InternationalStandardisation Organisation and SIS, Swedish Standards Institute (www.sis.se),amongst others.

A basic 600x400 mm module has been prepared by SIS in cooperation with the FMCGindustry. This module should guide the design of all types of packaging. It will then fit tothe pallet, whether it has dimensions of 800x1200 mm or 1000x1200 mm. The latter existsin some European countries.

When developing new packages, there are a variety of factors to consider. Amongthe most important is that the size is consistent with the different types of packaging.Consumer packages should be designed so that the outer packaging and pallet generatea good degree of filling.

For the flow of information to work, there is a set of rules available from GS1 atwww.gs1.org (or your national GS1 website). The GS1 item number (GTIN – Global TradeItem Number) and bar code should be on the consumer package and on outer packaging.Full-size pallets (display pallets) and, when appropriate, multi-unit packages should belabelled with GTIN for the top level as well as GTIN for the intermediate level belonging tothe multi-unit package; see chapter one, Item information.

Pallets should be labelled with GS1 Logistic Labels (Pallet labels). These labels includeinformation about the number of exterior packages and their GTIN. Different functions inthe flow of goods and information, such as arrival inspection, can be made more efficientusing scanning and/or sending messages via EDI.

There are also recommendations and industry agreements in place for item informationwww.gs1.org (or your national GS1 website), pallet height, etc.

ExceptionUnder certain circumstances, exceptions to the standard, industry agreements or similarmay be justified. An example is where the savings or efficiency gains at any stage exceedthe corresponding negative effects at other stages. Agreements may then be reachedbetween the parties involved. Exceptions are negotiated between buyer and seller.

LimitationsThe FMCG Packaging Guide addresses different kinds of packaging as a whole, in whichconsumer packaging is a part of the whole from producer to the store shelf, and storeshelf to the checkout. It addresses the function of the packaging, not its environmental

impact. The guide does not address consumer packaging from a strict consumerperspective, such as storage and how it is handled in the home.

INTRODUCTION


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Remember…The flow of goods and information includes many stages and there are players at eachstage with their own requirements for the packaging. These requirements vary dependingon the product and the relevant stage of the chain. Keep in mind that as a producer,

you must meet requirements set by all stakeholders in the logistics chain, not just theend consumer in the store. This is to ensure that the handling process is as efficient aspossible, without generating waste in the form of time and broken packages.

The requirements of the parties involved may include the following:

The supplierConsumer packaging and outer packaging should be easyto fill and seal. Packaging should be durable enough to with-stand physical handling in the warehouse and transportationenvironments. The package should be customised to carryits own weight and withstand double-stacking of pallets.The package should be labelled in accordance with the GS1

standard.

The distribution centreOuter packaging and pallets must be easy to identify, bothin plain text and with labelling in accordance with theGS1 standard. The bar code should be printed with clearcontrasts so it can be read by a scanner. Various types ofpackaging should be able to be mixed in a roller containeror on a loading pallet, without causing damage to goods.Outer packaging should be module-adapted to give thebest degree of filling in the roller container or on theloading pallet and facilitate logistics handling. Rememberto design outer packaging with holes punched at the short ends, if possible, to facilitateergonomic handling. The maximum weight of 15 kg applies to outer packages, which arehandled manually in the Swedish FMCG industry. Exceptions may be negotiated between

buyer and seller.

The storeOuter packaging must be labelled in order for thecontents to be easily identified. The bar code on theouter packaging as well as the consumer package mustbe clear enough to be able to be read by a scanner.The outer packaging must be easy to open and dis-play on the store shelf (shelf-ready). When the outerpackage is a tray, the edge should be sufficiently high,so that the consumer package stands steady once theouter packaging has been opened. Sales promotioninformation on the consumer package must be clearly

visible, even when the package is standing on a tray on the shelf. The number of consumerpackages in an outer package should be adapted to optimise the degree of filling whileensuring that store turnover rates for the item are fast enough.

TransportationPallet overhang may cause damage to goods andshould therefore be avoided (see chapter five,The Modular System). Clear labelling of pallets inaccordance with the applicable regulations (GS1standard) and any shipping labels. Two pallets, oneon top of the other, with a maximum pallet heightof 1250 mm per pallet, including the loading pallet,produce the best degree of filling and thereforelower transport costs.


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The ConsumerThe information on the package must be legible.The consumer package must be easy to open anduse. If possible, the consumer package should beresealable.

Packaging as a bearer of information At each stage of the flow of goods, the packaging plays an important role as a bearerof information. Consumer packages, outer packaging and pallets all convey information.Other terms used are primary, secondary and tertiary packages. The information is

presented as item numbers and bar codes, according to GS1’s regulations, as well asin plain text. Bar code labelling is one of the requirements for increasing operationalefficiency, both internally and between different players.

GTINs and bar codes on outer packaging and pallets are a means of achieving logisticalefficiency throughout the distribution chain. For example, it is a way of facilitating arrivalinspection and ensuring that the right pallet is received at and dispatched from the ware-house. It ensures that the right outer packages are selected from the pallet and the rightamount/weight is invoiced. Moreover, it ensures traceability in the form of expiry datesand batch numbers so that store recalls may be issued, such as in the case of productsafety alerts.

The consumer package may carry a list of ingredients, user instructions, expiry date anddetails about whom the consumer should contact for more product information. The con-sumer package must carry a bar code. This is registered in the store’s checkout to provide

consumers with information about the price of the product.

Bar code legibility and positioning on consumer packages, outer packaging, andpallets are important. The print must be of such quality that the bar code can be readby a scanner even after the package and the pallet have been handled throughout thedistribution chain.

In addition to being used as identification, the information carried by the package may beused for product tracking and origin labelling.

One piece of the jigsaw puzzle in an efficient flow of goods and information is thateach package carries item information (formerly VCD, read more in chapter one,Item information).

Item information includes data regarding the length, width, height, number of consumer

packages in an outer package, number of outer packages on a loading pallet, whether theouter package is a slotted crate or a wrap-around package, etc.

Bar code legibility andpositioning are important.

INTRODUCTION


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Chapter 1

Item Information

What does item informationhave to do with packaging?

The information exchange within the FMCG industry is an intensive and constant process.The exchange of information between retail companies and FMCG suppliers is increasingly

taking place electronically. Orders, advance delivery notes and invoices are examples ofbusiness transactions that are increasingly sent electronically. For an electronic flow ofinformation to work effectively, it is important that the parties have a common and correctbaseline.

When developing a new item and a new package, or changing an existing package, it isimportant that the buyer is informed of the properties of the items, packages and pallets.This is a prerequisite for correct orders and deliveries, but also for delivery planning, ware-house handling and shelf space in stores. In short, it is a prerequisite for an efficient flow ofgoods and information.

Part I The FMCG Industry


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Important to keep in mind

The regulations concerning the design and validation of item information arebased on a global standard.

Minimise all manual handling of item information and make use of the systemsolutions that are available on the market.

Poor and inaccurate data quality affects all stages of the supply chain andcreates substantial additional costs.

You can read more about iteminformation and Validoo Item atwww.validoo.se/en/our-services/ validoo-item. There is also a list of

verified system suppliers availablethere.

There are rules as to how differentpackages should be measured.You can read more at www.gs1.se/en/ elektronisk-handel/affarsprocesser/ packaging-guide.

Read more about the services onwww.validoo.se/en

GTIN (Global Trade Item Number), the packagelength, width, height, weight, the number ofconsumer packages within an outer packageand the number of outer packages on a palletcomprise some of the information that must besubmitted. Examples of other information thatmust be submitted include package type, storageconditions, item labelling (such as the KRAV-label), VAT information and information regardingregistration for paper recycling, such as REPA(Directory for producer responsibility) etc.

Item information is most easily sent via asystem supplier. There are a number of theseon the market. Their solutions often involve thecompletion of an online registration form on awebsite. To ensure that the information in the iteminformation is accurate, the details are sent viaValidoo Item. You may apply for this service atwww.validoo.se/en .

ITEM INFORMATION

How does it work?For a long time, FMCG suppliers in Sweden havesent item information (formerly VCD) to retailcompanies to ensure the correct logistical baseline

for the items. This is a prerequisite in order forthe supplier’s items to be sold in retail outlets. Inorder for the processing of item information to beincluded in the electronic information flow, GS1Sweden, amongst others, has developed a servicefor ensuring the quality of item information, calledValidoo Item. Validoo Q-lab is a service withinValidoo that conducts quality checks to ensurethat the consumer packaging and outer packagingcorrespond to the submitted item information.Quality assurance takes place in accordance withGS1’s global standardised rules of measurementand standards.


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Chapter 2

Consumer packaging

The consumer package must promote the sale of the product by means ofan appealing design, in addition to protecting and preserving the product.

Other factors to consider when designing a consumer package are product

information, size of the package, and that the package is easy to open and,as far as possible, to reseal.

The external dimensions of the consumer package are important. Alongwith the outer package, these must be adapted to the modular system; seechapter five, The Modular System. Consideration should be given to thematerial thickness of the outer package.

The fixtures in the store are another important factor to consider. Thefixtures in the store are adapted to the base module of 600x400 mm.

There are many varieties of consumer packages.


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Durable labelling and display

Labelling:“Consumer package” labelling should include a bar code, developed accordingto the GS1 standard, and plain text information, such as a list of ingredients.Read more in “Correct labelling” at www.gs1.se/global/om-gs1-sweden/ publikationer/correct-labelling-part-of-your-product-and-your-brand.pdf,which was jointly developed by SvDH, DLF and GS1. If the package containsgoods that are hazardous to health or the environment, additional speciallabelling is required. All labelling must be legible throughout the lifetime of thepackage – that is, at least as long as the specified best-before date.

If the package is on a tray, the print must be clearly visible above the edge ofthe tray.

Other names

for consumer packaging include:

• Consumer Unit (CU)• Consumer packaging/consumer package (CoP)• C-pack• Primary packaging/package• Multiple pack• Multi-pack• Inner packaging/package

CONSUMER PACKAGING


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Store shelf with consumer packages on display.

Adaptation to store display:The edge of the tray must be sufficiently high for the consumer package to stand securely.The tray must have sufficient material thickness in order not to fold when lifted, once theplastic and lid have been removed.

The size of the package must be adapted to the available shelf space for the productgroup in question.

The bottom surface and height of the consumer package should be adapted to thefixtures and shelf space in the store for the product group in question. Design the con-sumer packaging and outer packaging so they can be displayed as a unit. It must also bepossible to display the consumer package separately. Consumer packages that are to bedisplayed hanging (speared), must have punched and durable spear holes (Euro-holes).

It must be easy for the consumer to pick the product up from the shelf. Do not overwrapthe product.

Packages in contact with foodstuffs:When packaging material has direct contact with foodstuffs, a certificate should be drawn

up, such as the Normpack Certificate, declaring that the material has been approved forfoodstuffs. For more information, see www.normpack.se or www.li.se/om-li/in-english.

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40 0 –5 0 0

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The consumer package must promote the sale of the product by means ofan appealing design, as well as protecting and preserving the product.

Product information must be given on the package, the size of the packagemust be taken into account, and the package should be easy to open and, asfar as possible, to reseal.

The external dimensions of the consumer package are important. Alongwith the outer packaging, these must be adapted to the modular system,see chapter five, The Modular System. Consideration should be given to thematerial thickness of outer packaging and to ensuring that a good degree offilling is achieved.

“Consumer package” labelling should include a bar code, developedaccording to GS1 standard, and plain text information, such as a list of

ingredients. Read more in “Correct labelling” developed by SvDH, DLF andGS1, www.gs1.se/Global/Om-GS1-Sweden/Publikationer/Correct-labelling-Part-of-your-product-and-your-brand.pdf. If the package contains goodsthat are hazardous to health or the environment, additional special labellingis required.

Bar codes and other labels must be legible for at least until the specifiedbest-before date.

The edge of the tray must be sufficiently high in order for the consumerpackage to stand securely. The tray must have sufficient material thickness inorder not to fold when lifted once the plastic and lid have been removed.

Design the consumer packages and outer packaging so that they can bedisplayed as a unit. It must also be possible to display the consumer packageseparately.

Consumer packages that are to be displayed hanging (speared), must havepunched and durable spear holes (Euro-holes).

Do not overwrap the product.

When packaging material has direct contact with foodstuffs, a certificateshould be drawn up declaring the material has been approved for foodstuffs.For example, the Normpack Certificate. Read more in the “Guide to safe foodpackaging” developed by the Swedish Food Federation (Li) and Normpack.

CONSUMER PACKAGING


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Chapter 3

Outer packaging

In many cases, the outer package itself constitutes an orderable unit. Outer packaging isavailable in many different variations.

The primary role of outer packaging is to protect and hold consumer packages togetheruntil they reach the store shelf.

Outer packaging must be designed in a manner that enables easy identification, handling,storage, loading and re-loading on the way from producer to store. There, it should beeasy to open and any subsequent handling should be easy.

Pallets that come from producers are usually split at the distribution centre. Goods

from other producers are loaded together here. The goods are loaded together in rollercontainers or on loading pallets.

Other names forouter packaging include:

• Retail package/ packaging

• Display pallet• Prepack display• Secondary package/

packaging• Stock Keeping Unit (SKU)

• Trade Unit/Traded Unit

• Outer carton• Outer case• External package/

packaging• Store pack• Shop unit• Merchandiseable unit

• Case

The outer packaging should protect theconsumer unit; see part III Durable packaging.


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Shelf-readypackagingShelf-ready packaging (SRP) is a termused to describe an outer packagecontaining multiple consumer packagesready for placement on the store shelf.The purpose is to minimise producthandling between production and thestore shelf or shelf-end display.

An SRP package that is on the shelf, where the consumerpackage is visible, and should be easy to pick up.

Other names for shelf-ready packaging include:

• SRP• Shelf-ready packaging/package• RRP• Ready-to-sell packaging/package

OUTER PACKAGING


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Easy to identify

It is important to provide clearinstructions for opening

Easy to fold up for disposal.

Stability is important.

Shelf-ready packaging should be:

Shelf-ready packaging includes all types of packaging such as displays, pallets, trays, crates, etc.

Based on guidelines from ECR Europe and in close collaboration with the FMCG industry, ECR Swedenhas developed an evaluation form for shelf-ready packaging. The purpose of this tool is to facilitateSRP discussions between parties in the FMCG industry so that where appropriate, the SRP is usedeffectively throughout the chain. The evaluation form for shelf-ready packaging can be downloadedat www.ecr-europe.org.

Easy to open

Easy to display Easy to buy

Subsequenthandling should

be easy


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Display unitsand display palletsOther types of outer packaging includethe display unit and the display pallet.

According to GS1, these are regarded assellable units, i.e. outer packages. Standardpans or trays with products are oftenused, which are loaded together into adisplay pallet. In the development of newpackages, it is important to build on theexisting modular system; see chapter five,The Modular System. It is also importantthat the display unit or the display pallethold the weight of the products. For moreinformation, see part III, Durable Packaging,half-size pallets.

Multi-unit packagingMulti-unit packages may be used for a number of different outer packages, which may bedifficult to stock onto a loading pallet due to their shape. The multi-unit package is often atype of crate with an open top, or a lid that opens easily.

Goods are usually selected at the distribution centre where they are then loaded with othergoods ordered by the store. When selecting multi-unit packages, it is therefore not necessaryto consider store display.

Other names for multi-unit packaging include:

• Wholesale packaging/package• Handling Unit• Transport packaging/package• Multi-unit package

Disposable multi-unit packages.

Multi-unit package.Svenska Retursystem’s returnable crate.

OUTER PACKAGING


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LabellingInformation in plain text, GTIN and bar code must be included on outerpackaging; see chapter six, Labelling. Additional information may includesupplier item number, number of consumer packages in the outer package,

best-before date and batch number. If the package contains goods thatare hazardous to health or the environment, additional special labelling isrequired.

The multi-unit package does not need to be labelled, as its only purpose is tohold together a number of outer packages. It must not be possible to orderor subsequently sell the package as a single unit. However, the multi-unitpackage requires its own GTIN to enable identification and storage in variousdatabases.

GS1 recommends bar code labelling on at least one side. In cases of one-sidedlabelling, the principal rule is to apply strict orientation when placing theouter packages on the pallets. This means that packages are placed so thatthe bar codes are facing in the same direction as one of the two pallet labels;see strict orientation www.gs1.org (or your national GS1 website).


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High degree of filling for a more durable outer package; see part III,Durable packaging.

Module adaptation for outer packaging according to the dimensions of thepallet and desired height to facilitate mixed loading. See chapter five,The Modular System.

The sales rate for the product in the store should also be taken intoconsideration when determining the size of the outer packages.

Aspects to take into consideration at the design stage include whether outerpackages, pans or trays will be included in the display pallet, what it shouldlook like and how it should be handled.

A maximum weight of 15 kg applies to outer packages, unless the parties

have agreed otherwise.Identification throughout the supply chain. In addition to what is addressedin chapter six, Labelling, product names, size/numbers and/or item numberscan facilitate identification of outer packages in the store and warehouse.

It is preferable for labels on RRP to be located on the part of the packagewhich is removed when opening, or which is not visible to the consumer.

Outer packaging should be easy to open without the use of a knife.Any shrink-wrap used must be easy to remove.

Provide clear opening instructions for SRP, ideally with illustrations and aneffective opening device such as rip-tape or perforations that do not damagethe package decoration or labelling.

A stable tray that does not fold during handling once the plastic or lid has

been removed, and consumer packages must stand steady when displayed.The SRP package and the Consumer Package must look attractive together,consumer information must be visible and the Consumer Package must beeasy to pick up.

Facilitate subsequent handling of the package by adapting the amount ofmaterial to the requirements of each product, so it is easy to fold up anddispose of.

Packaging material for all packages – consumer packages, outer packages,multi-unit packages (if any) and pallets – must be selected so that thecombined environmental impact is as small as possible.

OUTER PACKAGING


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Chapter 4

Pallets

Full-size pallets(load carrier)800x1200 mm

• Grey returnable pallet from Svenska Retursystem.

• The EURO pallet – (SS-EN 13698-1).

• The CHEP pallet.

All can handle a load of 1000 kg, which is theweight limit for most pallet racks.

Load carriers are necessary to handle, transport and store outer packages in the supplychain. When outer packages are placed on the load carrier, the name Pallet is used.

The following types of load carriers are approved by the Swedish FMCG industry andindustrial catering industry.

Other common names

for pallets include:

• Unit load• Dispatch Unit• Tertiary package• Loading pallet• Load carrier• Transport pallet

Definition of pallet: Loading pallet with goods.

EURO full-size pallet

Full-size pallet fromSvenska Retursystem

CHEP full-size pallet


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PALLETS

CHEP half-size pallet

Wooden half-size pallet

Half-size pallet from Svenska Retursystem

Half-size pallets (load carriers)600x800 mm

• Returnable half-size pallet from Svenska Retursystem.

• The CHEP half-size pallet.

• Disposable half-size pallet (SS842004).

Ensure that the height of the pallet tunnel is 100 mm +/- 5mm.If it is lower, not all types of forklifts will be able to get in underthe pallet.

• Flex pallet: 2x(400x600 mm), see image. The flex palletmay be separated into two retail-ready display units. Thisdivisibility makes it possible to create a mixed pallet for twodifferent displays, which is great for shops that cannot order,for example, half-size pallets of an unmixed product. A retail-ready display greatly eases work in the store.

Half-size pallets and flex pallets are handled at the logisticsstage as one unit, all the way to the store.

Flex pallet

The height of the half-size pallet including thelayer pallet at the bottom, maximum 1250 mm


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Three different ways of loadingthe 800x1200 mm palletA loading pallet loaded with packages – may be created as:

• Unmixed full-size pallet.• Layer pallet.

• Mixed pallet.

Unmixed full-size pallet is the equivalent of the basic item information configuration(formerly VCD) and is loaded with the same item number on all outer packages.This is the most common kind of pallet.

The layer pallet is a split unmixed full-sizepallet, i.e. a loading pallet, which is loaded withone or more layers with the same item numberon the outer packages. Several different itemsmay also be stacked on top of one anotherto create a layer pallet; what is important is

that there is always a load carrier between thelayers of various items (see image). Just as forother pallets, the layer pallet should be labelledin accordance with the GS1 standard, whereevery pallet should have two identical labels(see p. 28 How to build a pallet).

The mixed pallet consists of a loading palletloaded with outer packages with differentitem numbers, where no one item makes up anentire layer. This type of pallet requires manualsorting when received and should be avoided.For more efficient delivery, it may be advan-tageous to put the various items on their ownload carriers and double-stack on top of an

unmixed full-size pallet.

Replace, hire or invoice loading pallet?Load carriers that are not disposable are handled via one of the following systems.

Returnable palletfrom Svenska RetursystemFor different charges combined with rents or deposits, you may “borrow” the loadcarrier for as long as needed. The load carrier does not need to be inspected and

no pallet exchange or PÖS takes place (see EURO pallet below). Find out more atwww.retursystem.se/en.

CHEP palletCharacteristic blue load carrier, which is arranged at a cost. The cost is eitherincluded in the price of the product or is invoiced separately. The load carrier doesnot need to be inspected and no pallet exchange or PÖS take place (see EURO palletbelow). The load carriers may be “hired” from CHEP for as long as needed from thefactory until returned to one of the CHEP depots. Find out more at www.chep.com.

Example of unmixed layer pallet.


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PALLETS

Approved EURO palletsFor the EURO pallet to be classified as approved, it should be manufactured in accordancewith the UIC Code 435-2, Swedish standard (SS-EN 13698-1) or the equivalent national standard.Find out more at www.sis.se (Search for 13698-1).

The EURO pallet willnot be approved if ithas one of the followingfaults…

A block is sosplintered thatthe nail shaftcan be seen.

A deck or bottom boardis so splintered that thenail shaft can be seen.

A stringer boardis broken.

The pallet is so dirty or damp,that goods may be damaged.

A board or a block is missing. A deck or bottom boardis broken.

EURO pallet(standard SS-EN 13698-1) The EURO pallet may be handled in various ways among sellers, haulage companies andbuyers. It is up to the parties to agree on this.

The three most common ways of handling a EURO pallet are:PÖS For a cost, the pallet transfer system (PÖS) regulates the exchange of ap-

proved EURO pallets via accounts between connected members. That is,both sender and recipient must be connected to the respective adminis-trator systems. System administrators in Sweden are Schenker, DHL, GreenCargo and Bring/Frigoscandia. If any related debts in EURO pallets are notsettled within the specified period, EURO pallets will be invoiced. Since notall businesses and haulage companies operating in Sweden are membersof PÖS, and do not want to regulate EURO pallets by invoice or palletexchange (see below), there are arrangements under which an account iskept for settling balances between two or more parties.

Pallet exchange The haulage company signs for an amount equivalent to approved EURO

pallets against pallets delivered. This occurs in relation to or in close

connection with delivery against pallet receipt.

Invoice EURO pallets that are imported/brought into Sweden are often invoicedto the recipient, either directly or via the price of the product. At the timeof writing 2012, it is not possible to settle with load carriers via PÖS forcountries outside of Sweden. As pallet exchanges across Swedish bordersare difficult for haulage companies, it is often the load carriers who areinvoiced.

As all handling of the EURO pallet above is based on approved pallets, disputes may ariseover EURO pallets, since to a certain extent the concept of “approved” is a judgment call.Therefore, it is important to establish how the EURO pallet is to be handled and regulatedbefore entering an agreement. This applies both to business agreements between buyers andsellers, and to agreements with haulage companies.


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Handling of pallets in a warehouse.

PALLETS


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How to build a pallet• Each layer must contain the same number of outer packages (with the exception of mixed

pallets). The finished pallet must be stable, stackable and easy to handle; read more in Part IIIDurable packaging.

• The total height including the loading pallet must not exceed 1250 mm. For transportation anddistribution purposes, the pallet should be built as close to the maximum height as possible.This makes it possible to make use of the maximum internal loading height of the goods vehicle.The pallet shelves in most warehouses are adapted to the standard height of 1250 mm.

• The pallet should always be labelled with two GS1 Logistic Labels (pallet labels). There shouldbe two identical labels, including bar codes and plain text information, placed as shown in theimage. Read more about GS1 Logistic Labels (pallet labels) in chapter six, Labelling.

• When transporting with a third party, a shipping label should be used to keep track of the palletwhile in transit and to meet the requirements of the logistics process, such as the tracking ofgoods. The label includes addresses, haulage company information and SSCC (Serial ShippingContainer Code, GS1 case number). If a shipping label is used in conjunction with a pallet label,the same SSCC must always be used. Read more about shipping labels in chapter six, Labelling.Shipping labels should always be applied to the outside of the plastic.

• If the pallet is wrapped in shrink-wrap or stretch-wrap, it must not be so tightly wrapped that thepackage becomes deformed. The same applies to pallets secured with transport straps.

• Pallets that are handled in automated process flows must be wrapped in plastic so that thepallet tunnels are free from plastic. Remember that the degree of automation increases everyyear.

• If adhesive tape is used around the pallet, there is a considerable risk that labelling anddecoration on outer packaging will be damaged when the tape is removed.

• If liners are needed to make the pallet stable, you should ensure that there is not a liner inbetween each layer of the pallet, if this is not necessary. The liners should be perforated sothat they can easily be torn off as the pallet is picked.

Location of the GS1 Logistic Label (Pallet label).

Maximum 800 mm

Minimum 400 mm

Minimum 400 mm

Maximum 800 mm


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Use a pallet approved by the Swedish FMCG and industrial cateringindustries.

Ensure that the loading pallet has the right labelling and appearance.

Build the pallet with the same amount of outer packages per layer.

A pallet made up of packages should be stable and easy to handle.

Always construct the pallet as near as possible to a height of 1250 mm.

Ensure that the load lashing is adapted so that no products are damaged.

The pallet must not exceed 1000 kg, including the loading pallet.

The pallet must be labelled with a standardised pallet label in accordancewith GS1 Logistic Label.

The labelling should be of such quality that it is legible until the pallet isbroken up.

Supporting documents for the item information (formerly VCD) must alwaysbe sent in case modifications are made to the number of outer packages,layers or load carrier type.

More and more pallets are handled in automatic process flows, which requirethat the plastic wrapping of the pallets does not cover pallet tunnels.

PALLETS


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To make effective use of production equipment,transportation and warehousing resources, storesystems etc, it is important to adapt all units tothe 600x400 mm modular system. This applies toconsumer packages as well as to outer and multi-unit packages. The modular system was developedby SIS in collaboration with the FMCG industry.This measurement standard is suitable for both800x1200 mm and 1000x1200 mm loading pallets.The latter are used in some European countries.For roller containers, the internal dimensions of800x660 mm apply.

Module-adapted outer packages(traditional retail containers as well asreturnable crates, plastic trays, etc.)on pallets in accordance with themodular system.

Module-adapted outer packages in rollercontainers produce a minimum amount ofair contact during transportation.

An efficient supply chain

is based on modules

1200

600

4 0 0

8 0 0

Chapter 5

The Modular System

6 0 0

40 0 – 5 0 0

9 0 0


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Basic modulesSeveral ideal modules are created on the basis of 600x400 mm base module. Whendeveloping consumer packages and outer packages, it is important to make use of theseideal modules. Keep in mind that the external dimensions of the consumer package

should fit the inner dimensions of the outer package. Therefore, it is important to plan forthe thickness of the package. The packaging material must be correctly adapted, neithertoo thick nor too thin for handling a normal load during transport, storage and handling.

600 x 400

Base module 600x400

Examples of ideal modules used in the FMCG industry.

Base module 200x400

Base module 300x400

Base module 150x400

300 x 400 200 x 400 150 x 400 120 x 400 300 x 200 200 x 200

THE MODULAR SYSTEM


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There are good alternatives that arenot included in the modular system

There are various dimensions which are perfectfrom a transportation and logistics point ofview and which give a good degree of filling onpallets and in roller containers. An example ofsuch dimensions is 265x400 mm. With thesedimensions, the layer of the pallet is interlockedand a stable pallet with a very good degree offilling is produced even though these dimensionsare not included in the modular system.

265x400

Tower stack of small modules

Pallets that are stacked up as towers with moduledimensions of 150x400 mm or lower, require linersto stabilise the pallet. The alternative is to lock

the layer with a pallet pattern, if possible, with thesame degree of filling.


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Svenska Retursystem modules

Returnable crates from Svenska Retursystem are good types of modules that in many casesrepresent suitable alternatives to traditional outer packages. These modules have greatadvantages over traditional retail packages; for example, they cause less crushing in the supply

chain and are a good environmental alternative thanks to their re-usability. The returnable cratesalso render logistics handling more efficient because crates may be handled in an automatedprocess flow. For more information, see www.retursystem.se/en.


Adapt the outer packages to the dimensions of the loading pallet. This is mosteasily done by reducing the dimensions of the outer packages by 5–10 mm perpackage. In practice, this means that an outer package in accordance with the

600x400 mm base module should have external dimensions of 590x390 mm.The material thickness added to the outer package must not be disregarded.

Adapt the consumer package to the inner dimensions of the outer package toobtain the highest possible degree of filling. Calculations must take into accountthe thickness of the outer package.

Returnable crates are an environmentally friendly alternative that reducecrushing and handling problems in the supply chain while being easy toautomate.

Always test pack before establishing the final dimensions.

Use liners for pallets stacked as towers with small modules.

Note that the module dimensions of 120x400 mm are not adapted for an

automated process flow.Keep in mind that other dimensions may work well as modules for pallets andouter packages.

600x400x194 mm

400x300x193 mm

600x400x167 mm

400x300x148 mm

600x400x106 mm

400x300x(50/80) mm

Svenska Retursystem provides 6 different modules that are used in the FMCG industry.

THE MODULAR SYSTEM


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Chapter 6

Labelling

GTIN and bar codesGS1 item number (GTIN) and bar code labelling must be used for the consumer package,outer packaging and pallet. For multi-unit packages, only GTIN applies.

In Sweden, registration and coordination is managed by the GS1 system of GS1 Sweden.

You can find more information regarding access to the GS1 system at www.gs1.org (or your national GS1 website).

GTIN (Global Trade Item Number) is used for numbering packages and depending onthe area of use, one of the following GTINs should be used; GTIN-13, GTIN-8, GTIN-14or GTIN-12. The number forms a basis for orders, warehouse accounting and statistics.Therefore, it is a requirement for all packages to be assigned a GTIN.

GTINs are international, which means that the same number should be used regardlessof the country in which the item is to be sold. The item number is divided into three parts.GS1 company prefix, item number and a final control digit (K). GTIN 14 starts with an LV-code, a number between 1–8, where LV is the abbreviation for logistical variant. Select anumber between 1–8 (LV code) for placement in front of GTIN-13 to create the GTIN-14.Please note that the item directory should always include 14 digits (aligned to the right).


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GTIN-8

GTIN-8 is used for packages on which the space for a GTIN-13 is limited. GTIN-8 includeseight digits and may only be used on consumer packages. 10 items at the most may benumbered with GTIN-8.

GTIN-14

GTIN-14 cannot be read at the store checkout and is therefore only used for numberingouter packages and pallets. Numbering with GTIN-14 means that GTIN-13 on the innerpackage is used in combination with an initial logistic variant, LV code, a number between1–8. A new control digit is calculated.

• The LV code can take be any number between 1–8 on unit goods.

• The LV code 9 signifies that it is an item with varying weight.

GTIN-13GTIN-13 contains 13 digits. Numbering of the item normally takes place at the facilities ofthe producer, who orders a GS1 company prefix representing the GS1 for the country inwhich the organisation is located.

When numbering and applying bar codes to items of varying weights, it is also a require-

ment to order a GS1 Variable weight prefix.

This prefix is national and intended for products with varying weights. GS1 Variable weightprefix may only be used on the consumer package.

Choosing the numbering principleThe consumer package is numbered with either GTIN-13 or GTIN-8. The outerpackages and pallets are numbered with either GTIN-13 or GTIN-14. For moreinformation on the numbering of weight products www.gs1.org (or your nationalGS1 website).

Example 1:Numbering with GTIN-13

Consumer package: 73 5000000 001 6

Outer package: 73 5000000 002 3

Pallet: 73 5000000 003 0

Position 14 13 12 11 10 9 8 7 6 5 4 3 2 1(K)

GTIN-13 0 7 3 5 0 0 0 0 0 0 1 2 3 5

GTIN-8 0 0 0 0 0 0 7 3 0 0 1 1 1 9

GTIN-14 1 7 3 5 0 0 0 0 0 0 1 2 3 2

GTIN-12 0 0 0 1 2 3 4 5 6 7 1 2 3 4

Numbering of packages may be conducted in accordance with four different structures.

Example 2:Numbering with GTIN-13 or GTIN-14

Consumer package: 73 5000000 001 6

Outer package: 1 73 5000000 001 1

Pallet: 2 73 5000000 001 0

LABELLING


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Bar codesThe EAN-13 bar code may only include GTIN.It has four different line widths. Therefore, high-quality printing is required for it to be legible.

The ITF-14 bar code may only include GTIN.It has two line widths. This makes it readable witha scanner, even if it is printed or written in ink jet,for example, directly on corrugated cardboard.

Example 1:

Numbering with GTIN-13 Bar code alternatives

Consumer package: 73 5000000 001 6 EAN-13

Outer package: 73 5000000 002 3/073 5000000 002 3 EAN-13, ITF-14, GS1-128

Example 2:

Numbering with GTIN-13 or GTIN-14 Bar code alternatives

Consumer package: 73 5000000 001 6 EAN-13

Outer package: 1 73 5 000000 001 1 ITF-14, GS1-128

The EAN-13 bar code is the most commonlyused on consumer packages.

In most cases, the ITF-14 bar code has two

line widths and a frame. It is used for outerpackaging.

The bar code GS1-128 makes it possible toenter both GTIN and other information.

The GS1-128 bar code can include informationadditional to one GTIN. Date, as well as best-before or packing date, data for traceability suchas batch number or serial number and, if appli-cable, weight data.

GS1-128 requires the same high quality of printingas EAN-13.


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Choice of bar codeThe consumer package should be labelled with either bar code EAN-13 or EAN-8.These bar codes can be read at store checkout counters.

Outer packaging is labelled with any of the GS1-128, EAN-13 or ITF-14 bar codes.When GTIN-13 is used in the bar codes ITF-14 or GS1-128, GTIN-13 should start with a zero.

For bar code labelling of pallets, a standardised pallet label should be used, GS1 LogisticLabel (GS1 Pallet Label). The pallet label bar code should follow the bar code formatGS1-128. More information about pallet labels is provided below and a completedescription is available at www.gs1.org (or your national GS1 website).

Bar code printing qualityThe bar code should be legible until the item is no longer offered at retail level or has

expired, according to the item’s “best-before date”. Printing quality of the bar code mustbe equal to the “Overall Symbol Grade C” quality specified in ISO 154 16. This means thata minimum of “Overall Symbol Grade B” should be achievable when printing.

In many cases, printing directly on outer packaging results in poor legibility, particularlyif printing is done on brown corrugated packaging. Adhesive labels are preferable toprinting directly on brown corrugated packaging.

Example of bar code labelling onconsumer packages EAN-13.

LABELLING

Bar code labellingof consumer packagesConsumer packages are labelled with bar code EAN-13 orEAN-8. The bar code on consumer packages should besimple and quick to read at the checkout or point of sale.Bar code quality depends upon the colour of lines andbackgrounds, line width, the size of the bar code, heightand light margins. Read more at www.gs1.org (or your national GS1 website.)


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Bar code label locationon the consumer package• A label with a bar code is placed at least 8 mm from the edge of the package.

• Labels with bar codes must never be placed around corners, over joints, perforations orseals.

• The bar code is placed on a smooth surface.

• The bar code must not be placed below the joints on transparent film.

• The bar code must not be placed on the bottom of the package.

• The bar code is placed standing, like a ladder, on round cans or other cylindrical shapedpackages with diameters of less than 120 mm.

• Each package must have only one visible bar code (including multi packs).

Bar code labelling ofouter packaging

The outer package may be labelled with any ofthe EAN-13, ITF-14 or GS1-128 bar codes accordingto the GS1 standard. Choose bar code dependingon area of use and the amount of informationthat needs to be transferred via the bar code. TheSwedish FMCG industry recommends that outerpackaging be labelled with GS1-128, as this barcode can contain more information than EAN-13and ITF-14, such as batch number, best-beforedate or weight. Read more about labelling ofouter packaging at www.gs1.org (or your nationalGS1 website).

The location of the bar code on theconsumer package is important.

An example of outer package labelling (GS1-128).


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LABELLING

Package type GS1 item number Bar code

Consumer package GTIN-13GTIN-8GTIN-12

EAN-13EAN-8UPCAUPCE

Outer packages GTIN-13GTIN-14

EAN-13, ITF-14, GS1-128ITF-14, GS1-128

Bar code label location on theouter package• There must be a bar code label or a bar code printed directly on the package. Labelling

on at least one side is recommended but labelling on more than one side is preferred.

In case of one-sided labelling, the outer packages should be placed on the pallet so thatthe label is on the same side as one of the pallet labels.

• The bar code must not be placed on the bottom of the package.

• The bar code must be placed so that the lower edges of the lines are 32 mm +/– 3 mmfrom the bottom of the package. For ITF-14, the bottom edge of the frame around thebar code should be 27.2 mm above the bottom of the package. The frame is 4.8 mm.The distance between the side of the package and the bar code should be at least19 mm.

• For labelling of returnable crates, the label material used should be approved bySvenska Retursystem to facilitate removal and cleaning of returnable crates. Moreinformation at www.retursystem.se/en.

• Maintain and clean printing heads and printers in the production environment to ensureretention of good printing quality.

• Avoid printing the bar code on brown corrugated packaging as it results in poorlegibility. Adhesive labels are preferred.

Outer packages with labelling on two sides.


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Pallet labelPallets must be labelled with GS1 Logistic Label (Pallet Label). The pallet label is necessaryfor identification of the pallet in your own handling at the warehouse, upon receipt ofgoods and for logistics management. The bar code on the pallet label must follow the

GS1-128 bar code format. Correct pallet labelling generates faster and more efficientlogistics handling as well as traceability throughout the value chain. When information inthe pallet label corresponds to the physical item and the supplier labels the pallet in thecorrect manner, it is not necessary for the wholesaler to re-label the goods during thisstage of the supply chain. Logistics handling is more efficient and goods are availablemore quickly in the warehouse. The quality of delivery to the store increases as manualhandling and the risk of errors decrease. This in turn provides improved delivery capacit yto the store. The risk of goods selling out on the store shelf is decreased and productavailability to the end consumer increases.

Example of GS1 Logistic label. Example of shipping label.

From AB Elektronikimport, Stockholmc/o TredjepartslogistikIndustrigatan 35S-291 54 HELSINGBORGTel: +46 (0)42-87 56 18 Date of sending

October 14 1999To Karlsson & Son Montering AB Fabriksvägen 33

S-522 07 FALKÖPING Diagonally across the yard, yellow door Order no: 5678-99

Delivery inst.

Space for codes according to each hauliercompany’s instructions

Transportföretaget AB Economy packageNotification is sent for CODs

Hazardous goodsSending-ID 476 733 249 9 Case 2 / 7 Weight 37 / 350

Postal code: (421) 208 633 0

Unique case number: (00) 373 99999 1234567899


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The pallet label must not be confused with the shipping label. The shipping label includesdelivery information such as address, haulage company information and SSCC (SerialShipping Container Code, GS1 case number). If a shipping label is used together with apallet label, the same SSCC must always be used. Read more about shipping labels atwww.gs1.org (or your national website).

LABELLING


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Label placement of GS1 pallet label on pallet• The pallet must be labelled on two connected sides – one short side and the long side to

its right.

• The bar codes on the label should be at least 400 mm, and at most 800 mm, from the

bottom.• The label should be placed as high as possible within this range, but if required, leave

space for the shipping label above the pallet label.

• The pallet label should be placed on the outside of the plastic wrapping. However. If thepallets are mixed, the pallet label should be placed on top of the load under the plasticwrapping.

• No label must be closer than 50 mm to the edge of the pallet.

Pallet label.

The pallet mustbe labelled on twoconnected sides.

The shipping label mustbe above the pallet label.

The pallet label must beat least 400 mm, and atmost 800 mm, from thebottom.

Multi-unit package GTIN-13GTIN-14

Pallet GTIN-13GTIN-14

GS1 Pallet labelGS1 Pallet label


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LABELLING


Select the bar code depending on area of use and the amount of informationthat needs to be transferred via the bar code.

GS1-128 provides the opportunity to add additional information such as batchnumber, best-before date and weight.

The legibility of the bar code must be at least “Overall Symbol Grade C”.

Conduct continuous maintenance of printers and equipment to ensure goodprinting quality is retained.

The bar code must be placed to facilitate reading by recipients and atcheckouts or points of sale.

Avoid printing the bar code on brown corrugated packaging as it leads topoor legibility. Adhesive labels are preferred.

Placement of the GS1 Logistic Label (pallet label) is important because manycustomers use automated warehouses that are adapted to read the labelaccording to the GS1 standard (at least 400 mm, and at most 800 mm,from the bottom).


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Part II Restaurants and Industrial Catering

In many respects, packages in the restaurant and institutional catering sector are similarto those in the FMCG industry. However, there are differences that must be addressed inorder to create a comprehensive common packaging guide.

The difference is mainly with respect to the appearance of orderable units and pallet con-figuration. It is also important to note there are different names used to refer to packagerecipients, in the FMCG industry, a store or possibly a consumer is the final destination,while in the restaurant and industrial catering sector, the term end-user is used (such asindustrial catering, restaurant).

Item InformationSupporting documents with item information for Movement Certificates are now widelycoordinated between the Restaurant and Industrial Catering sector and the FMCGindustry. Read more about Item information, part I chapter one.

PalletThe height of the pallet varies greatly in the restaurant andindustrial catering sector due to extensive importing and the1250 mm as a guideline for pallet height is not customaryoutside Scandinavia. Many pallets are higher – generally neverlower.

Since many outer packages are designed so that palletisingproduces pallets not able to be double stacked, this occursonly to a limited extent.

One example is that of buckets, as in the image above.Fragility of the packages may be another reason, for examplesacks of flour. See examples below. Read more about Pallets,part I chapter four.

Restaurantsand Industrial Catering

The packageThe restaurant and industrial catering sector uses the namesprimary (consumer package) and secondary package, whichare often the same orderable unit. Usually the inner packagehierarchy is missing, as they are not normally sold in retailstores.

The outer package (secondary package) is also used by theFMCG industry and refers to the package that is normallypacked on pallets. The outer package is the orderable unit.

In the restaurants and industrial catering sector there is no ruleregarding the outer package exceeding a weight of 15 kg; forexample, bag-in-box milk packages (20 kg) and flour sacks(20–30 kg).

Read more about packages, part I of chapters two and three.See also part III Durable packaging to ensure good packagequality.

Examples of orderable units inthe Restaurants and IndustrialCatering sector.


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Requirementsfor outer packaging

The goods should travel safely all the way to the store.This requires packages that work throughout the wholelogistics chain, so that the supply flow can happen quicklyand cost effectively. This guide contains joint industryrecommendations with detailed requirements for outerpackaging.


Module adaptation for outer pack-aging is an important considerationin the development of new products.This is to facilitate the degree of

filling of pallets and roller containersand to obtain an optimised supplychain. See part one, chapter five,The Modular System.

The weight of the outer packagemust not exceed 15 kg.

Returnable crates from SvenskaRetursystem should, if possible,replace ordinary retail packages,with regard to perishables as wellas fruit and vegetables.

Opening instructions should beincluded in the packages if it is notalready apparent on the packageas to how it should be opened. This

makes it easier to unpack the goodswith the right side up, which mayalso contribute to reducing crushingduring handling and transportation.

Punched handles and holes in theouter package facilitate ergonomichandling.

The whole way from the producerto the factory, outer packaging mustprotect the product.

Part III Durable packaging FROM FACTORY TO STORE


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Outer packaging should be tough enough to cope with...

Being lifted by the lid Being pulled by the tab

Being lifted or pulled by the plastic


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Common errors to avoid

Remember: Each outer package should have a degree of filling that is as high as possibleso that the consumer package may contribute to stability and strength, and help reduceenvironmental impact.

Risk: In case of a poor degree of filling, the outer package will have poorer compressivestrength, which can lead to crushed and deformed outer packages when pallets arestacked on top of one another. An outer package with a poor degree of filling alsooccupies more space during transportation, which leads to an increased transportationrequirement and increased costs.

Remember: If the outer package is perforated, theperforation must be able to cope with the straininvolved with transportation to the store. It shouldbe able to withstand selection, storage and thepressure of double-stacked pallets.

Risk: Each perforation makes the outer packageweaker. If the perforation is too weak, the outerpackage may rupture and the consumer packageswill be damaged.

Weak perforation

Poor degree of filling


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Remember: Lids must always be secured on

outer packages with glue, tape or other meansof securing. Risk: If the lid is loose, the consumer package mayfall out and be damaged.

Remember: When wrapping shrink-wrap over theouter package, the purpose of the shrink-wrap isto protect the consumer packages from impactand ensure that the consumer packages do notfall out of the outer package.

Risk: Excess shrink-wrap longer than 5 mm maypose the risk of the outer package becomingcaught and getting stuck during transportation.It is especially important to consider that theproduct must be able to withstand being handledin an automated process flow. When wrappingwith shrink-wrap, it is important to verify thatthe design of the consumer package does notcontribute to an unstable outer package.

Defective shrink-wrapping

Loose lids

REQUIREMENTS FOR OUTER PACKAGE

Remember: An outer package designed as a traywithout lid or shrink-wrap should have a tray edgethat is equivalent to half the height of the con-sumer package or at least 50 mm. It is especiallyimportant to consider that the product must beable to withstand being handled in an automatedprocess.

Risk: If the tray edge or the tab on the short side istoo low, the consumer packages may fall out of theouter package. This is especially applicable to drygoods and frozen goods, not to returnable crates.

Edge of tray too low

5 0 % o f X o r a t l e a s t 5 0 m m

X mm


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Remember: The outer package must be constructed in such a way that it protects theconsumer package all the way to the store. Therefore, it must always be fitted with a lidor shrink-wrap so that the consumer packages are held in place.

Risk: Without sufficient protection, the consumer packages may fall out during handlingand risk being damaged by other products when loaded together on roller containers and

pallets.

Unprotected products

Remember: The quality of corrugated cardboardused for the outer package must be adapted tosuit the shape and the weight of the product, andany tray/bottom must be stiff and of good quality.

Risk: If poor quality corrugated cardboard isused, the outer packages may be deformed whendouble stacking. If the quality is poor, consumerpackages may fall out of the tray after the lid/plastic has been removed.

Substandard cardboard


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REQUIREMENTS FOR OUTER PACKAGING

Remember: Both the gluing and the corrugatedcardboard must be able to withstand normalhandling of the outer package. The strength ofthe gluing and corrugated cardboard at the pointof gluing must be tested under actual storageconditions for at least 10 days.

Risk: Glue leakage is the most common problemwith regard to deficiencies in outer packaging.It may only take one spot of glue to leak duringhandling for the construction to rupture and resultin crushing and repacking at the logistics stage.

Remember: The dimensions of the outer packages should be module-adapted.See part I in chapter five, The Modular System.

Risk: Poor module adaptation leads to a poor degree of filling of roller containers andpallets, which in turn results in more expensive transportation, handling problems at thelogistics stage and greater environmental impact.

Glue leakage

Poor module-adaptation of outer packages


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How to test glue strength

Glue leakage – the most common defect!The outer package must be able to hold all the way to the store. The strength of the gluedtabs play a crucial role in how well the package manages this. In fact, glue leakage is thesingle most common reason for the rupturing of packages.

Here we explain how to measure the glue strength, the equipment used for measuring andthe quality requirements.

What you need:– Dynamometer– L-shaped hitch block

The design of the hitch blockPlease note that only height (A) and width (B)on the part of the hitch block behind the tab ismeasured; the other measurements will not affectthe result. The length of the hitch block must notbe more than 100 mm for the sake of stability.

Exceptions to hitch block measurements may bemade in terms of height (A) in the event packagedimensions do not allow the use of standardheight.

A 50 mm

B

2 5 m m

Package with glue leakage.


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How to measureTo measure the strength of a glued tab, measureat the following points:

– 20 mm towards the centre for each glue point– the centre of the tab

The L-shaped hitch block is placed behind thetab at each measuring point. The point is subjectto pulling until the glue or the cardboard leaks/ ruptures. The value shown on the dynamometerat the time of rupture indicates the load the gluepoint is able to handle.

Where should you measure?

In the example to the left, there are two glue pointson each side (circles). Measuring point A is shifted20 mm towards the centre of the edge of the gluepoint. Measuring point B is in the middle of the taband measuring point C is placed 20 mm towards thecentre from the edge of the second glue point. Incases where there are one or more glue points in themiddle, the pulling tool must be placed 20 mm oneither side of these.

Quality requirements for glued tabsAll tabs on an outer package should, 3 months after the production date, be able to withstanda pull of at least 44 Nm in the middle (B) and 22 Nm on the sides (A, C) without the glue leakingor the cardboard rupturing.

A B C

20 mm

A B C

20 mm


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Packaging for automation

Ratio

Ratio is a simple way to determine the likelihoodof an outer package tipping over. The requirementis for all packages to have a ratio value of no morethan 1.5.

For products that are intended to go through an automatedprocess, there are specific quality requirements that shouldbe taken into consideration. In this section, we addressthese quality requirements. Remember we have previouslydescribed quality requirements that applies to both manualand automated processes.

ExampleCrate dimensions: 450x300x250(HeightxWidthxLength)

Ratio calculationMaximum value ((450/300) (450/250))Maximum value ((1.5)(1.8))Maximum value = Ratio = 1.8

This crate has a ratio of 1.8 and is thereforenot suitable for an automated process.

The following calculation is used:

(h/l)≥1.5≤(h/w)

The highest values of (heightdivided by length) and (heightdivided by width) may notexceed 1.5.


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Flat bottom

Example of packages with flat bottoms that may behandled in an automated process.

Example of packages with plastic protrusionsand unevenness at the bottom of the corrugatedtray. These packages may not be handled in anautomated process.

Example of packages without a tray, which results inan uneven bottom.

Remember: The underside/bottom of an outerpackage should be flat. For example, an envelopebottom is not classified as flat. There must notbe any plastic protrusions (excess shrink-wrap)underneath. Also check to make sure there areno deformations on the first layer closest to thepallet when the pallet is packed at production.Deformations may be caused by substandardcorrugated cardboard, non-modular adaptedcrate dimensions, or a combination of these.

Risk: An uneven underside/bottom may result instoppages and damage in an automated productflow.

PACKAGING FOR AUTOMATION


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Recommendations

for pallets

Full-size pallets

Good quality pallets and pallet configurations are requiredin order to achieve a fast and sustainable supply chain.The most important aspects that must be considered arelisted below:

EURO full-size pallet

Full-size pallet fromSvenska Retursystem

CHEP full-size pallet


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Standard height of the pallet is amaximum of 1250 mm, includingthe pallet at the bottom.

Approved pallets for use in theFMCG industry are EURO, CHEPand returnable pallets fromSvenska Retursystem. All withdimensions of 800x1200 mm.

Double stacking. The palletshould be well wrapped andpacked in such a way that twopallets may easily be doublestacked without the outerpackage being damaged.


Remember: To obtain a stable pallet configuration for a larger number of smaller outerpackages on a pallet, it is necessary to interlock the layers. If the modular system isfollowed, liners must be used between the layers for stability of modules with dimensionsof 150x400 mm or below.

Risk: Tower stacking of smaller outer packages often results in unstable pallets thatcollapse easily during handling and after unwrapping.

Not interlocking the pallet layers

Example of tower stacked pallet.Pallets with interlocked layers.

RECOMMENDATIONS FOR PALLETS


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Remember: The wrapping of outer packages occupies space. It is therefore importantto start with the actual dimensions when creating a pallet pattern to fit a pallet of1200x800 mm in size.

Risk: If the pallet is over-dimensioned, overhang is created, which leads to damage duringtransportation. A pallet with overhang also results in handling problems at the warehouse.

Overhang on pallets

Remember: A pallet box is a good way of handling and protecting small and glossy typesof packaging and is also more economical as there is no need to handle transport packages.A pallet box should not be used for anything other than full-size and half-size pallets if it isto be handled in an automated process.

Risk: Outer packages containing fragile products such as plastic wrap with flour, soil, etc.could easily be broken if a pallet box is not used for loading, delivery and unwrapping in thewarehouse.

Fragile goods prone to damage

The outer packaging is not adapted tothe size of the pallet.

Crushing due to overhang.

Example of pallet box. Example of products that shouldbe handled in a pallet box.


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Remember: Use corner supports or straps for palletsthat would otherwise have needed further wrapping/ plastic wrapping. This facilitates warehouse handling,saves money and is a more environmentally friendlyalternative. Also remember that automated processeshave specific requirements for liners. These should bemade of corrugated cardboard, not be too thin andnot have more than one liner per layer. If possible, usethe liners that are separable by way of perforation.This facilitates order selection at the warehouse.

Risk: Remember not to use several liners per layer,since this cannot be handled in an automated process.

Unnecessary wrapping

Too many liners on the pallet and also notdivisible.

Good example without plastic, wrappedwith plastic strips.

Bad example with steel stripsand wooden collar.

Remember: The degree of pallet filling mustbe high. Especially important is the short sidealong which the outer packages must reachthe whole way from one edge to the other, i.e.800 mm.

Risk: A poor degree of filling creates the risk ofcollapse during transportation and handling, aspallets may not be double-stacked.

Poor degree of pallet filling

Unstable double stacking.



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Height of half-size pallet including the full-sizepallet at the bottom is 1250 mm maximum

CHEP half-size pallet

Half-size pallets

Wooden half-size pallet

Half-size pallet from Svenska Retursystem

Mixed palletsRemember: If mixed pallets are used when theclient has not bought whole layers of items, the

pallet must be mixed in such a way that there isno risk of damage or impact on the packages. Itis recommended that whole layers of productsare bought. In this case, there should be a palletbetween the products. This means multiple layerpallets can be stacked together during transpor-tation or layer pallets or incomplete layer palletsused as top pallets during transport.

Risk: Mixed pallets create additional handlingat the logistics stage, which results in a slowersupply flow. In addition, with mixed pallets, thereis a risk of impact to the outer packaging whenseveral products are mixed together.

Good examples of unmixed layer pallets.


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The height of the pallet must be amaximum of 1250 mm, including boththe half-size pallet and the full-sizepallet at the bottom.

Recommended pallet types are:Wooden half-size pallets, CHEP half-size pallets and half-size pallets fromSvenska Retursystem.

The dimensions of the half-size palletmust be 600x800 mm.


Remember: When planning half-size pallets,it is important that wrapping is done properlyso that the pallet is stable.

Risk: If the boxes are heavy and glossy, thesemay slide off the pallet, resulting in collapse anddamage.

Poor wrapping of half-size pallets

Example of half-size pallet with no wrapping.

Remember: If a half-size pallet solution for a heavyproduct is packed with a blind bottom, it must beof high enough quality to be able to handle theload.

Risk: Blind bottoms raise the centre of gravityof the pallet, which causes problems with forklifthandling. The pallet then becomes unstable and

there is a risk that it will tip over.

Poor package construction

Half-size pallet configuration with a blind bottom

that has tipped over.



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By using a cover of corrugated cardboard on the half-size pallet, the palletbecomes more stable and less likely to tip over. At the same time, the productis protected from impact. If possible, use as little extra wrapping/plastic aspossible. If the solution is stable, it will be enough to use plastic straps andpossibly corner supports. Also remember that the wrapping should be withinthe pallet dimensions of 600x800 mm. Do not over-dimension the pallet.

Wrap the half-size pallet with cardboard covers

Recommendations for half-size pallets

Good examples with cardboard covers.


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Pallets for automation

Plastic wrapping of pallettunnels

Remember: The tunnels under the pallet mustbe free from plastic and there must not be anyplastic hanging loose.

Risk: Pallet tunnels covered with plastic cannotbe handled in an automated warehouse as theyrisk being rejected from the automated guide-way system. If pallets need to be re-layered, thisresults in a slower supply flow. Loose hangingplastic may cause a stoppage in an automated

warehouse.

Plastic is not allowed in indicated areas.Examples of covered pallet tunnels.

Pallet quality

It is very important that the palletsmaintain a high and even quality, i.e.class A. Very few types of damageto the pallet can be accepted.Recommended pallet types areEURO pallets, CHEP pallets andpallets from Svenska Retursystem.

Overhang and inclination

of palletsRemember: Pallets should be constructed withoutoverhang and without any inclination.

Risk: If the pallet does not keep to the dimen-sions, it may be rejected from the fixed guidewaysystem in automated warehouses. Any such errorsmust be corrected manually, which is not alwayspossible and leads to an inefficient and slow flowof goods.

For more information about palletsand pallet quality, see the links below:

http://www.retursystem.se/enhttp://www.chep.comhttp://www.sis.se

Example of an inclined pallet in an automatedwarehouse.


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