Category: Blog

New Distributor Packs!

Posted on by teamA-GG

We wanted to post this short blog to let you know about a new product we have! Complete Packaging Systems is pleased to announce that we now sell dunnage bag kits called Distributor Packs! Distributor packs are made up of 60 – 30” x 30” Over-the-Road CYCLONE dunnage bags with two bonus inflators included. These convenient, small box quantities are perfect for distributors with low dunnage bag usage and include the tools needed to inflate the bags.

Regular, full-sized pallets of dunnage bags contain large pallet quantities, which are great for shippers using dunnage bags on a regular basis however, these large pallet quantities can be overwhelming for companies only requiring dunnage bags for uncommon shipments. The Distributor Pack contains the perfect small quantity of dunnage bags for infrequent users, or one-time shipments as the pack has two inflators for customers that may not already have inflation tools on hand. The Distributor Pack is also small enough that it can easily be shipped via ground carrier to different locations when in a pinch, ensuring you can always have the cargo securement products you need when loading your product.

Dunnage bag inflators usually connect to compressed air lines, but if your facility does not have a compressor, we have a still have solution for you! Discuss our portable, battery powered inflator options with one of our sales representatives for added portability, and to eliminate the need for compressors and run lines.

To find out more about our Distributor Packs, or to discuss other options that meet your shipping requirements, speak with one of our knowledgeable technical sales and service representatives today by calling 1-866-858-8800.

 

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Metals Industry – LoadSecure™ 8260

Posted on by teamA-GG

Complete Packaging Systems supplies LoadSecure™ 6910 rubber friction mats as an effective, safe and cost- efficient replacement to traditional wood blocking and bracing, which are manufactured with a maximum working C.O.F. (Coefficient of Friction) rating of 1.2g. This C.O.F. value exceeds the required securement Performance Criteria rating of 0.8 g during forward deceleration events and 0.5 g when providing securement for cargo shifting to the sides and rear directions of the trailer or container, this per U.S. FMCSA 49 CFR and Canada National Safety Code 10 Regulations.

However, did you know that Complete Packaging Systems offers another grade of LoadSecure™ friction mat well suited for the Metals Industry? LS – 8260 provides all the benefits of our standard LoadSecure™ mat, but is a superior alternative based on ASTM dynamic test results for Tensile, Tear, Elongation and Density properties. Having  greater density (lbs./cu.³) equates to greater strength and durability necessary to withstand the load bearing forces typically realized when shipping finished products in the form of, but not limited to: Billets, Ingots, Pigs, Logs, Coil, Plate and Wire.

Given product being shipped in the metals industry can be extremely heavy, it is typically shipped on skids instead of pallets. Skids are often built with only 2-3 runners and have no bottom crossing boards. Meaning, the weight of the product on top of the skid is displaced across a much smaller load bearing footprint. The above conditions result in greater shear type forces and dynamic demand being applied to the mat.

Other industries typically ship their product on pallets. Pallet design often incorporates as many as 5 boards that travel perpendicular to the runners. The weight from the product on top of the pallet is distributed across these 5 boards and therefore less weight onto the load bearing surface area. LS – 8260  provides measurably more durability at load bearing points underneath skids and is best suited for the heaviest of cargo securement requirements.

LoadSecure™ 8260 friction mat incorporates the same high-vis printing as our standard LoadSecure™ friction mat, to identify the C.O.F. rating of 1.2 g. This assures North American friction mat compliance with all Roadside Enforcement agencies. Product is available in pre-cut sheets, rolls, perforated rolls and in thickness ranging from 2mm – 6mm.

Given this grade of mat is typically used in the metals industry, LoadSecure™ 8260 is also very effective for other applications requiring securement of extremely heavy Cargo or for shippers who want to be able to reuse their friction mats.

For more information or to speak about your Cargo Securement application, please contact us at 866-858-8800!

 

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Paper Vs. Polypropylene Dunnage Bags

Posted on by teamA-GG

In this blog we will discuss the benefits of choosing polypropylene dunnage bags over paper dunnage bags when used in cargo securement. Complete Packaging Systems recommends our CYCLONE polypropylene dunnage bags over paper dunnage bags because of the cost, space, recyclability, valve technology and durability benefits of polypropylene bags when compared to paper dunnage bags.

Cost and Space Savings

Polypropylene dunnage bags are typically cheaper and take up less space than paper bags. Just one pallet of polypropylene bags is equal to approximately 2-3 pallets of paper bags. Having more bags per skid will take up less of the valuable space on your warehouse floor. More polypropylene bags per pallet also means the freight costs per bag will be lower than when shipping paper dunnage bags because you won’t need as many pallet spots in a carrier truck for polypropylene bags as you would for the same amount of paper dunnage bags.

Recycling Polypropylene bags Vs Recycling Paper Bags

Polypropylene bags are easier to recycle than paper dunnage bags. When recycling paper bags, the plastic bladder inside the bag needs to be removed and recycled using a plastic recycling method, while the outer layer of the bags will need to be recycled using a paper recycling method. When recycling polypropylene bags, the inner bladder and outer woven layer of the bag can be recycled in the same way.

Inflation and Valve technology comparison

Paper bags tend to have old style valve technology that can lead to slow fill times and air leaks. There is also typically no deflation mechanism built into the valves on paper bags. CYCLONE polypropylene dunnage bags contain the latest valve technology with a spring-loaded valve to ensure the valve closes tightly and no air leaks out of the bags. The valve on CYCLONE bags also contains a deflation cap, providing a safe and easy method of deflating the dunnage bags at their destination.

Overall Durability

The outer kraft layer of paper bags is more fragile than polypropylene dunnage bags, making them more prone to rips and tears. Polypropylene bags contain a durable outer layer consisting of woven polypropylene material that is less susceptible to any rips and nicks that the bag may be exposed to during transit. Polypropylene dunnage bags are also great for use in loads that may be exposed to water, whereas the outer layer of the paper bags would not hold up well in damp conditions (ex. humid conditions in ocean containers).

Overall, polypropylene dunnage bags are a superior choice to paper dunnage bags as they are more cost-effective, more space-efficient, contain advanced valve technology and are more durable to the environment around them. For more information about our CYCLONE dunnage bags, speak with one of our knowledgeable technical sales and service representatives today by calling toll free at 866-858-8800.

 

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System Strength of Synthetic Cord Strap

Posted on by teamA-GG

When trying to determine the proper strength of synthetic cord strap needed in your load plan there are two types of measurements commonly referred to – Break Strength and System Strength – but what do these mean? Below are descriptions of each of these terms and why they are just some of the important terms to know when trying to decide which type of synthetic cord strap you need to secure your cargo.

Break Strength (also referred to as Tensile Strength):  The Break Strength of synthetic cord strap is the amount of force (commonly measured in pounds or dekanewtons) that a piece of strap can withstand before breaking and/or splitting. The Break Strength of strap is used to determine the strength of the synthetic cord strap alone, without the addition of a buckle (i.e. Joint Efficiency).

Joint Efficiency: Joint Efficiency is a percentage of the strap strength with the incorporation of a wire buckle or ladder buckle. The Joint Efficiency is critical when trying to calculate the System Strength.

System Strength: System Strength is the force (commonly measured in pounds or dekanewtons) required to break a unit of strap. This consists of one loop of strap and one buckle used to connect the ends of the strap, forming a “belt loop”. The System Strength can be found by multiplying two times the Break Strength of the strap by the Joint Efficiency of the buckle (Ex. System Strength = (Break Strength x 2) x Joint Efficiency).

Below is a diagram of the different types of measurements being tested.

When trying to obtain the proper System Strength of your strap, it is important that the same strap and compliant buckle combo are being used that was originally tested to achieve the AAR approval. Using an unapproved strap and buckle combination can lead to a different System Strength and cause your load to be non-compliant. The approved strap and their corresponding buckle can be found on the AAR’s website in Table 19.2 of the AAR’s Open Top Loading Rules. The list of AAR approved strap for doorway protection can be found in the AAR’s publication “Nonmetallic Strap Substitution for Steel Strap as Doorway Protection in Boxcars”.

Please note, not all the factors that need to be considered when choosing a strap for your load plan were mentioned in this blog. Understanding Break Strength, Joint Efficiency and System Strength will provide you with a good start on your search for your cargo strap. For more information about the strength of synthetic cord strapping and the corresponding buckles, speak to one of our knowledgeable technical sales and services representatives by calling us toll free at 866-858-8800.

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PSI Levels for Dunnage Bags

Posted on by teamA-GG

Dunnage bags are a versatile and easy way to fill voids in load plans, but there are user recommendations for dunnage bags the operator should follow. In this blog, we will describe the importance of filling your dunnage bags to the recommended PSI level in order to use the dunnage bag safely and obtain the optimal performance of the bag. This blog will also explain the consequences of not following the PSI level recommendations and provide some easy tips to help you get the proper PSI level when filling your dunnage bags.

What is the PSI Level of dunnage bags and where can it be found?

The dunnage bag PSI level is the measurement of air pressure within the bag measured in Pounds per Square Inch. When you fill the dunnage bag with air, the air pressure will build inside the dunnage bag, reading as the PSI. In Europe, they use the pressure measurement of kPa (kilopascals) to measure the pressure within dunnage bags. One kilopascal is equal to 0.145038 PSI. Each type of dunnage bag will have a different recommended PSI or “fill” level. The recommended PSI level should be printed on the bag itself. On our CYCLONE dunnage bags, the PSI level is printed on the front of each bag in a text box filled with user recommendations. To the right is an image depicting the user recommendations on our CYCLONE dunnage bags with the recommendations outlined in red for reference.

Consequences of not following the dunnage bag recommendations:

Filling your dunnage bag to the recommended PSI level allows for the optimal function of the bag during transit. Under filling a dunnage bag can lead to unwanted product movement as the bag will not tightly fill up the void, leaving room/spaces for your product to move into during transit. If you overfill a dunnage bag this can cause the bag to pop and/or split especially if there is a large amount of pressure applied to the bag. If the bag pops during transit then the void the bag was filling will open, allowing room for your product to move and possibly become damaged during transit. If a dunnage bag pops while an operator is handling the bag, this can cause harm to the operator. Although dunnage bags are easy to use, everything has a breaking point when used incorrectly. Following the guidelines for filling dunnage bags will lead to the best outcome of the dunnage during transit.

Tips for obtaining the proper PSI level in dunnage bags:

  • The dunnage bag should be filled using an approved inflator for your dunnage bag and the bag’s specific valve design.
  • Your dunnage bags should be cared for and stored according to the manufacturer’s recommendations.
  • Use a digital or manual air gauge to check the PSI fill to ensure you have reached the optimal PSI reading.
  • The AAR recommends rechecking the air pressure in all dunnage bags 30 minutes after the initial inflation.
  • Use clean and dry air to fill the dunnage bags.

 

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T-Loading Pulpboard Rolls

Posted on by teamA-GG

When shipping pulpboard rolls in cushion-equipped boxcars, more rolls can be shipped in a single railcar by using an on-side or T-Loading method. T-loading consists of loading the first layer of rolls into a railcar using an AAR approved loading pattern then adding a second layer of rolls on top, placed in bilge position. This creates a “T” like pattern with the pulpboard, as shown in the diagram below from the AAR’s publication Best Practices for Loading Roll Paper in Railcars. To secure the pulpboard, each roll on its side must have a chock placed underneath it and there must be a blocking roll at or before the doorposts at the A and B end of the railcar. Chocks used under the pulpboard must be of an appropriate height and width, whether they are built up corrugated chocks or rubber alternatives. Blocking rolls must be slightly higher than the adjacent rolls in the first layer. This can be accomplished by using a slightly taller roll or by placing risers underneath the blocking roll to increase its height. The top of the blocking roll, along with the chocks, will stop the second layer of pulpboard from rolling towards the doorway area of the railcar. When T-loading, the doorway must be loaded and secured using an AAR approved method. Shippers should advise the consignee that these loads contain two layers with rolls placed on their sides, so they are properly equipped when unloading the shipment.

T-Loading is only AAR approved for certain roll sizes and with certain commodities. Please ensure you review section 6.6 of the AAR’s Best Practices for Loading Roll Paper in Railcars to see the full guidelines and restrictions for the use of T-Loading methods. For more information about securing T-Loaded railcars or to find out if T-Loading can be used when shipping your pulpboard rolls, contact us toll-free at 866-858-8800.

T-Loading AAR PulpboardT-Loading Pulpboard AAR

 

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Creating a Great Load Plan

Posted on by teamA-GG

A perfect way to generate a safe load plan when preparing to ship your product in a closed car is by referencing the AAR (Association of American Railroads) Loading Guides for your commodity combined with the use of load plan software. The AAR publications ensure you are following industry regulations while load planning software allows you to review the plan from multiple angles. The AAR has a general rule guide for shipping products in closed railcars called Circular 42-N. Circular 42-N covers topics from Inspection and Selection of Cars to the Center of Gravity Special Equipment. The AAR also has individual closed car loading guides for a variety of different commodities. The individual load guides outline specific regulations and load patterns created just for the product you are shipping. If any additions or adjustments are made to the AAR loading guides, the AAR will issue a General Information Series (GIS) regarding the update, allowing industry regulations and safety guidelines to continuously improve and be accessible. These AAR publications will provide the information you need to ship your product safely in a closed railcar and indicate what cargo securement products are required for your load plan.

With the AAR publications providing you all the regulatory body information you need; load planning software can help you put those rules and regulations into a 3D view. New load plan software has been developed making it easier for many users to navigate and design load plans. Developing a 3D drawing of the load plan can help the loader fully understand the load plan, determine what cargo securement products may be required and ensure that nothing has been missed or overlooked. Load planning software includes, but isn’t limited to Google SketchUp Pro, Load Xpert, LoadPlanner, and Cargo-Planner.

If you would like to confirm your load plan is up to industry standards and believe generating a 3D drawing of your load plan would be beneficial for you and your team, get in touch with one of our knowledgeable technical sales and service representatives by calling toll-free at 866-858-8800.

What Are Contour Buffer Pads?

Posted on by teamA-GG

When shipping roll paper, it can be difficult to find a product that fills voids between paper rolls due to the curved, rounded shape of the rolls. Contour buffer pads are designed to help stabilize dunnage bags and other cargo securement products used to fill voids within roll paper shipments. Contour buffer pads contain one side that lines the shape of the roll paper while the side adjacent to the roll is a flat surface for dunnage bags or void filler to easily be applied to. The flat surface of the contour buffer pad helps prevent the dunnage bag or honeycomb being used to fill the void from curving to one side and shifting around the roll. The diagrams from the AAR’s Closed Car Loading Guide – Loading Roll Paper in Rail Cars below show how the contour buffer pads create a flat surface for the void fillers or dunnage bags to rest on.

 

Contour buffer pads allow you to get more surface area contact between the paper rolls and the void fillers/dunnage bags you are using. However, contour buffer pads are not considered as void fillers in a load plan. This means that any contour buffer pads used will not be counted towards the maximum number of void fillers and dunnage bags you can use within a load space. Although contour buffer pads can increase the effectiveness of dunnage bags, the loader is still required to find the center line of the two rolls they are trying to secure and ensure that the bags and contour pads are properly positioned. Failure to do so can still result in the bag being jettisoned out of the void post-impact. For more information about contour buffer pads and how they can be used in your load plan, contact us toll free at 1-866-858-8800.

 

 

Edited by: Stephanie Irvine

Images above from AAR’s Closed Car Loading Guide – Loading Roll Paper in Rail Cars

2019 AAR Damage Prevention & Freight Claim Conference

Posted on by teamA-GG

As in previous years, Complete Packaging Systems was delighted to attend the Annual AAR Damage Prevention and Freight Claim Conference held last month. This year’s 127th Annual AAR DP & FC Conference was held in Omaha, Nebraska from July 8th-11th 2019. The three-day conference covered a variety of industry updates, trends and developments that occurred over the past year.

The conference began with an overview of the Paper, Automotive and Food & Beverage Industry. The overviews included manufacturing outputs, sales and consumer trends. Union Pacific’s Mexico Franchise and Union Pacific’s Cold Connect operations were also discussed.

The bulk of this year’s conference focused on three major “breakout” rail shipments in the industry: Paper, Open-Top and Automotive. The Paper Breakout portion of the conference provided a 101 session for Roll Paper Load Plan Creations covering load plan software, shipment trials and obtaining AAR Approvals. The Open-top Breakout portion of the conference covered topics such as pipe shipments, required railcar clearance updates, the development of new securement products in open-top shipments, military vehicle shipments and how drones have become useful for rail safety/monitoring. Finally, the Automotive breakout session of the conference discussed updates to quality and training sessions, vehicle inspections and how the changes in modern car designs is changing the way cars need to be shipped.

The conference ended with an overview of railcar fleet trends, rail industry updates, factors affecting and creating changes in our industry, the effects of spring deflection on center of gravity height, intermodal distribution and a preview of changes for 2020.

The amount of industry updates and knowledge that Complete Packaging Systems was able to acquire at this years AAR DP & FC Conference was outstanding. Every year there are new technology and safety developments that help improve the rail industry. A full breakdown of this year’s AAR DP & FC Conference and some of the presentations can be found at the AAR’s webpage. For any questions regarding cargo securement and your load plan, contact one of our knowledgeable technical sales and service representatives by calling 866-858-8800.

Woven Vs. Composite Strap

Posted on by teamA-GG

Two of the most popular types of strap used in the cargo securement industry are polywoven and composite. Both are great products to use when securing your cargo, but there are differences between the two that make each one more suitable for certain load applications.

Polywoven strap is made up of polyester fibers that are woven together. Its strength comes from the way the fibers are woven in a multi-directional pattern, weaving both horizontally and vertically. The composition of polywoven strap allows it to have flexibility while providing good tension on rigid loads. The woven material provides slight elongation of the strap, helping it absorb some of the shock and impact during transit while still maintaining its position.

Composite strap is made up of strands of polyester fibers, all traveling vertically and coated together by clear polypropylene. The polypropylene coating increases its resistance to abrasion, yet still allows for slight elongation during transit. Due to its polypropylene coating, composite strap is much stiffer than polywoven strap. The stiffness of composite strap makes it easy to feed underneath pallets.

Both woven and composite strap have different wire buckles that are intended to be used with each type of strap. The difference is the finish on the buckles. For woven strap, you should use phosphate coated wire buckles. The phosphate coating on the buckle allows for more friction against the woven material. If composite strap were used with the phosphate coated wire buckles, the strap would become worn from the friction between the buckle and strap. Instead, for composite strap you should use galvanized wire buckles. The smooth finish of the galvanized buckle allows the composite strap to thread effortlessly on the buckle and stays in place because of the stiffness of the strap. If woven strap were used with the galvanized buckles, the strap could slip off the buckle as there would be no friction between the buckle and strap to hold the strap in place.

In order to get the maximum effectiveness from your cargo securement products, it is important the correct products are used together. To find out more about the products you should be using in your load plan contact us toll free at 866-858-8800.