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5.2 Protective Packaging Selection

Final protective packaging is the critical defense against the hazards of the logistics chain. It must protect the finished product from shock, vibration, and environmental degradation during transit and storage. Packaging is the last control gate, validating the physical and electrical integrity of the entire assembly against abuse beyond the factory floor.

5.2.1 ESD Barrier and Layering Mandate

Packaging must provide both electrical and mechanical protection through specific material layering.

A) ESD Protection Protocol

  • Shielding Bag Mandate: Finished assemblies must be sealed inside a metal-in shielding bag (Faraday cage) to prevent external static events from damaging sensitive components. Standard "pink anti-static" bags are insufficient for shielding.
  • Stack Order (Inside – Out): The required layering is: Product – Dissipative Layer (foam/tray) – Shielding Bag (closed) – Cushion – Carton.
  • Dissipative Materials: Only materials with dissipative surface resistivity (104 – 1011 Ω/sq) are permitted to touch the product. Insulative materials (raw bubble, plain plastics) are prohibited.
  • Ground Path: Carts and totes carrying WIP (Work In Progress) must bond to the ESD floor; operators must still strap until the shielding bag is fully sealed.

B) Moisture and Climate Control

  • Long Haul/Humid Routes: For ocean freight or long-term storage, add a calculated amount of desiccant (silica gel) and a Humidity Indicator Card (HIC) inside the carton.
  • Prohibition: Avoid materials prone to shedding (e.g., specific PU foams) near windows or vents, as this introduces FOD.

5.2.2 Mechanical Integrity and Cushioning Selection

Cushioning must be engineered based on the product's weight and fragility rating (G-rating).

A) Cushioning Sizing (Floating Mandate)

  • Float the Product: The product must be centered within the carton, maintaining a minimum clearance of ≥ 25 mm to every wall. For heavier units (≥ 8 kg), float clearance must be increased (≥ 50 mm).
  • Weight-Based Sizing (Rule of Thumb):
    • ≤ 2 kg: 20 – 30 mm foam each side.
    • 8 kg+: ≥ 50 mm foam + edge blocks.
  • Center of Gravity (CG): Packaging must support the heaviest ends; use drop bridges so corners and structural elements absorb impact energy, not the bezel or sensitive panels.

B) Cushion Material Choices

Material

Best for

Pros

Watch-outs

EPE Foam (Expanded PE)

General electronics (light–med weight).

Inexpensive, cuttable, good rebound.

Not suitable for heavy point loads.

XLPE Plank

Heavier units, edge blocks.

Strong, clean edges, excellent shock resistance.

Requires specialized tooling for cutting; higher cost.

Thermoformed Trays

WIP, high-volume light products.

Precise nests, stackable, repeatable.

Custom tooling required; limited to one orientation.

Molded Pulp

Eco-forward, single-use.

Recyclable, stiff structure.

Dust potential; requires good design.

5.2.3 Final Pack Architecture and Verification

The final carton architecture and labeling must ensure safety, stacking, and compliance.

A) Unit Pack Architecture

  • Primary Protection: Shielding bag sealed; connector caps and plugs fitted.
  • Secondary Protection: Cushioning material (foam, corrugated) placed to control orientation and prevent abrasion (no rubbing on labels or gaskets). Accessories must be placed in an isolated bay so they do not press against the product.
  • Carton Integrity: Board grade (ECT/double-wall) must match the weight and stack height. Prohibited: No overhang past pallet edges.

B) Verification and Acceptance Cues

  • Fit Check: Shake test must result in no product rattle.
  • Quick Test: Perform the Drop Test (5–10 drops from route height) on a sample to verify the product and carton survive cosmetics and function.
  • Acceptance Cues: Carton must be clean; UP arrows and fragile labels (if needed) must be correct; pallet pattern must be square on deck with corner boards installed.
  • Data Linkage: All packaging labels mirroring identity (SN, MAC) must be printed from the MES only.

Final Checklist

Mandate

Criteria

Verification Action

ESD Barrier

Unit sealed in a metal-in shielding bag.

Pink anti-static bags are prohibited as the sole barrier.

Cushioning

Product centered with ≥ 25 mm float; zero internal rattle.

Shake test confirms no product movement or abrasion risk.

Moisture Control

Desiccant and HIC included in the MBB (Moisture Barrier Bag).

MBB must be fully sealed; HIC color verified prior to closure.

Material Usage

Only dissipative/conductive materials permitted to touch the product.

Insulative materials (raw bubble/peanuts) are prohibited.

Carton Integrity

Board grade/ECT sized to weight; no overhang on the pallet.

Corner boards installed for vertical stack protection.

Labeling

Orientation, fragile, and regulatory marks are correct and aligned.

Printed labels (SN/MAC) must match data pulled from the MES.


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