Windscreen Protection in the Automotive Industry
The client engaged with us to develop a tailored AIR|SHIELD inflatable protective system, creating an on-demand inflatable barrier around each windscreen.
The Challenge
The client supplies windscreens and panoramic glass to multiple aftermarket retailers and Car Dealers across the Globe. Their existing packaging system involved corrugated cartons with foam buffers and corner guards, which led to:
- High breakage rates during transit due to insufficient cushioning
- Bulky packaging and high transport costs
- Manual handling challenges and inconsistent pack performance
- Difficulty scaling for different glass sizes and curvatures
Our Solution
The client engaged with us to develop a tailored AIR|SHIELD inflatable protective system, creating an on-demand inflatable barrier around each windscreen.
AIR|SHIELD Key Features for Windscreens:
- Custom-fit inflatable wraps and edge buffers for varied windscreen sizes
- On-demand inflation at packing stations to reduce storage and waste
- Designed to form a rigid air-cushioned shell, absorbing shock and vibration
- Flexible enough to accommodate both flat and curved glass
- Integration with standard outer cartons or custom crates
Results after 3 Months
| KPI | Pre-AIR|SHIELD | Post-AIR|SHIELD |
|---|---|---|
Transit Breakage Rate | 4.1% | 0.4% |
Avg. Packaging Time (per unit) | 6 mins | 3.5 mins |
Storage Footprint (protective packs) | 10 Pallets | 2 Pallets |
Pack Material Weight per unit | 2.8kg | 0.9kg |
Recyclability of Materials | 55% | 70% |
Results & Impact
The client engaged with us to develop a tailored AIR|SHIELD inflatable protective system, creating an on-demand inflatable barrier around each windscreen.
AIR|SHIELD Key Features for Windscreens:
- Custom-fit inflatable wraps and edge buffers for varied windscreen sizes
- On-demand inflation at packing stations to reduce storage and waste
- Designed to form a rigid air-cushioned shell, absorbing shock and vibration
- Flexible enough to accommodate both flat and curved glass
- Integration with standard outer cartons or custom crates
"This has been a transformative shift for us. We’ve reduced glass damage dramatically while freeing up space and reducing packaging waste. Our warehouse team love the simplicity, and AIR|SHIELD gave us a flexible packaging model for our growing product range."
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Let's discuss how we can create a custom solution for your specific needs.