How CakeBoxx Containers Strengthened Supply Chain Efficiency and Environmental Impact at Boeing ✈️

🚫 Inefficient and Unsustainable Wooden Crates

A team at Boeing was looking to replace single-use wooden crates that were used to ship horizontal stabilizers for Boeing aircraft with a more sustainable option that could also offer better protection during transport.

🤝 A Thorough, Collaborative Approach

We approached the challenge in the same way we approach all projects – by examining the challenge thoroughly through clear channels of communication with the customer and devising a unique, problem-solving solution with them.

🚀 Introducing an Innovative Solution

After closely collaborating with Boeing’s engineers and transportation team, CakeBoxx developed a unique 45-foot container. This container was specifically engineered to accommodate the horizontal stabilizers while fitting within existing ISO standard container sizes.

Key features of our solution included:

• Two-Piece Form Factor: The unique two-piece design of the CakeBoxx container was central to the solution. By separating the lid from the deck, we eliminated the need for large side doors or complex loading mechanisms. This design allowed for easy access to the horizontal stabilizers from above, simplifying the loading and unloading process. It also enhanced the security of the cargo, as the lid is securely fastened to protect against environmental factors and unauthorized access during transit. Additionally, the two-piece form factor reduces handling risks and potential damage to the stabilizers, ensuring that these high-value components remain secure and intact throughout their journey.
• Half-Height Construction: The half-height (4’9”) design was another crucial innovation. This size was specifically chosen to accommodate the thin profile of the horizontal stabilizers, which would have resulted in significant dead space if transported in a standard container. By reducing the height of the container, we optimized the internal space, ensuring a snug fit for the stabilizers and eliminating wasted volume. The lower profile also improves stability during transport, reducing the risk of tipping or shifting. Furthermore, the half-height construction makes these containers easier to stack and store, providing additional logistical flexibility and efficiency.
• Corner Guides: To ensure the smooth and accurate operation of the container, we incorporated corner guides into the design. We offer these guides on all our two-piece containers, and while they are not essential, are recommended for high-consequence cargo. This feature is particularly beneficial in fast-paced or less-than-ideal conditions, where precise alignment in removing or replacing the lid might be challenging. The corner guides help handlers quickly and correctly secure and lift the lid during loading and unloading, reducing the time spent on alignment and minimizing the potential for damage during this process. This ensures that the integrity of the container is maintained, protecting the stabilizers from external elements.
• Viewing Ports: We included small, strategically placed high-strength polycarbonate viewing ports in the container’s lid, enabling inspectors to verify the contents without having to open it. Interior mounted, externally powered LED lighting illuminates the payload area for cargo verification. By reducing the frequency of lid openings, the risk of cargo damage or compromise is minimized. Additionally, the viewing ports facilitate smoother and faster customs clearances.

The implementation process involved close collaboration between CakeBoxx and Boeing, with weekly meetings to discuss progress and make necessary adjustments. Our ability to work together as an integrated team was key to the project’s success.

🌱 Sustainable Operations & Significant Cost Savings

The containers, which travel between manufacturing and assembly plants in the U.S. and internationally, have proven to be highly efficient and cost-effective. Unlike the previous wooden crates, which were single-use, the CakeBoxx containers are durable and reusable, leading to significant cost savings and reduced environmental impact, supporting a greener supply chain.

🌍 Global Success

Over the past decade, 62 specialized containers have been produced for Boeing, all of which remain in active service – demonstrating long-term reliability and ROI.

✅ Conclusion

CakeBoxx Technologies’ innovative approach to optimized transport and storage solutions has not only solved a critical transportation challenge but also set a new standard for efficiency, safety, and sustainability in the aerospace industry. The partnership on this project between the two companies underscores the value of CakeBoxx’s problem-solving capabilities and commitment to supporting our customers’ strategic goals.