New crating system eliminates previous damage issues, streamlines the packaging workflow, and provides a durable and reusable asset.
26 February 2026
The Challenge
Our military customer was suffering losses due to file safes being damaged during transit. The existing palettization method alone proved insufficient for the weight and sensitivity of the units.
Beyond the cost of equipment repairs, the client was struggling with lost time, coordinating frequent re-shipments, and transporting challenges.
The Larson Packaging Solution
Larson Packaging designed a modified, toolless rack-style crate tailored for easy use and protection. The design featured a felt-lined well and a secure cap to lock the safe in place during motion. By utilizing external pallet cushions instead of a standard internal floater, the team reduced the crate’s overall height. This allowed the safes to be slid directly from the warehouse pallet into the crate, significantly reducing labor time and the risk of drops during transfer.
The Result
Following a collaborative virtual design review, the customer adopted the solution. The new crating system eliminated the previous damage issues, streamlined the packaging workflow, and provided a durable, reusable asset for their logistics chain.