• Advertise
  • Contact Us
  • About Us
  • Supplier Directory
  • SCB YouTube
  • Login
  • Subscribe
  • Logout
  • My Profile
  • LOGISTICS
    • Air Cargo
    • All Logistics
    • Express/Small Shipments
    • Facility Location Planning
    • Freight Forwarding/Customs Brokerage
    • Global Gateways
    • Global Logistics
    • Last Mile Delivery
    • Logistics Outsourcing
    • LTL/Truckload Services
    • Ocean Transportation
    • Rail & Intermodal
    • Reverse Logistics
    • Service Parts Management
    • Transportation & Distribution
  • TECHNOLOGY
    • All Technology
    • Artificial Intelligence
    • Cloud & On-Demand Systems
    • Data Management (Big Data/IoT/Blockchain)
    • ERP & Enterprise Systems
    • Forecasting & Demand Planning
    • Global Trade Management
    • Inventory Planning/ Optimization
    • Product Lifecycle Management
    • Sales & Operations Planning
    • SC Finance & Revenue Management
    • SC Planning & Optimization
    • Sourcing/Procurement/SRM
    • Supply Chain Visibility
    • Transportation Management
  • GENERAL SCM
    • Business Strategy Alignment
    • Education & Professional Development
    • Global Supply Chain Management
    • Global Trade & Economics
    • HR & Labor Management
    • Quality & Metrics
    • Regulation & Compliance
    • SC Security & Risk Mgmt
    • Supply Chains in Crisis
    • Sustainability & Corporate Social Responsibility
  • WAREHOUSING
    • All Warehouse Services
    • Conveyors & Sortation
    • Lift Trucks & AGVs
    • Order Fulfillment
    • Packaging
    • RFID, Barcode, Mobility & Voice
    • Robotics
    • Warehouse Management Systems
  • INDUSTRIES
    • Aerospace & Defense
    • Apparel
    • Automotive
    • Chemicals & Energy
    • Consumer Packaged Goods
    • E-Commerce/Omni-Channel
    • Food & Beverage
    • Healthcare
    • High-Tech/Electronics
    • Industrial Manufacturing
    • Pharmaceutical/Biotech
    • Retail
  • THINK TANK
  • WEBINARS
    • On-Demand Webinars
    • Upcoming Webinars
    • Webinar Library
  • PODCASTS
  • VIDEOS
  • WHITEPAPERS
Home » Campbell Solves a Sticky Situation Through Quick Response to Packaging Glitch

Campbell Solves a Sticky Situation Through Quick Response to Packaging Glitch

December 1, 2005
Global Logistics & Supply Chain Strategies

In January 2005, Campbell Soup Co. received word from a Food Lion distribution center that there was a problem with the corrugated cases that contained bottles of V8 juice. The glue, it seems, wasn't holding together, causing the cases to break apart during order picking.

One month earlier, Campbell had begun shipping 32- and 46- ounce plastic bottles of V8 and tomato juice in enclosed corrugated cases. As with other Campbell-made beverages in bottles of 32 ounces or more, the new case design featured a cut-out display "window" through which the product could be seen. The new packaging for V8, produced by Campbell in Napoleon, Ohio and shipped to three DCs in the eastern U.S., began reaching retailers in January.

Problems arose almost immediately. On Jan. 10, a Food Lion buyer alerted Campbell by e-mail of the glue defect. Right away, Campbell agreed to accept returns on any beverage product that was experiencing a packaging glitch. Then it went to work on the cause.

Campbell's logistics manager informed the Napoleon beverage plant of the glue issue. Meanwhile, Food Lion sent a second e-mail with pallet and product codes for the faulty packaging. That was followed by digital pictures to document the problem.

The culprit, according to Food Lion, was defective or insufficient glue on the bottom flaps. In addition, DC personnel were using the display window on the corrugated boxes as a handle, to lift during picking. That left the bottoms unsupported-an unforeseen side-effect of the new design.

Campbell's suppliers of corrugate, glue and shrink-wrap were brought into the picture, meeting with manufacturing and packaging research to solve the problem. They quickly initiated test runs for a new packaging design, which would include finger holds on the sides for more efficient lifting and picking. At the same time, the glue maker, National Starch and Chemical Co., arranged to visit the Napoleon plant to check on glue temperature, pressure, amount and placement.

Within a few days, Campbell had decided to switch over to a package that was fully enclosed, without the front display cutout. For a quick fix, Campbell informed Food Lion that all future shipments of V8 and tomato juice in the 32- and 46-ounce bottles would be shrink-wrapped for extra case strength.

Campbell then turned its attention to product that had been packaged but was yet to be shipped. At its three DCs serving the eastern U.S., it strengthened the cases of all existing inventory of 32- and 46-ounce plastic bottles, either through shrink-wrap or tape. Approximately 100,000 cases were reworked, the company says.

The long-term fix was implemented on Jan. 25. It consisted of the newly designed cases with finger holds, increased amounts of glue and a new glue pattern for more holding power on the flaps. Campbell placed some test cases in cold storage overnight, simulating conditions in cold weather months to see if the glue would crystallize and weaken.

In response to Food Lion's complaint, Campbell did more than simply apply more glue or strengthen the boxes. It accepted costly returns, then came up with an entirely new case design. And the whole process, from initial notification through design, testing and implementation, took just 15 days.

"I appreciate all that's been done to help us on our damages," says Randy McGuire, warehouse manager with Food Lion. "I don't think I've ever seen a problem like this tackled so fast and with so much dedication to the customer."

    RELATED CONTENT

    RELATED VIDEOS

    Global Logistics & Supply Chain Strategies

    Transplace Helps Del Monte Streamline Network

    More from this author

    Subscribe to our Daily Newsletter!

    Timely, incisive articles delivered directly to your inbox.

    Popular Stories

    • AN ARRAY OF MEDICAL DEVICES LAID OUT ON A GREEN BACKGROUND

      Why the Medical-Device Industry Is Embracing Contract Manufacturing

      Sourcing/Procurement/SRM
    • A TOY TRUCK CARRIES A GIANT BOX WITH A RED RIBBON IN A BOW

      Three Trends to Watch During Peak Season 2023

      Apparel
    • A MANUFACTURING PLANT AT DUSK OR DAWN REFLECTED IN WATER

      Uncertainty is the New Normal

      Data Management (Big Data/IoT/Blockchain)
    • On Demand Webinar_SAP.png

      Optimize your Logistics Pinch Points to Build a Risk Resilient & Sustainable Supply Chain

      Webinars
    • A GIANT CONTAINER VESSEL SPORTING THE LETTERING OF YANG MING PLIES THE SEAS

      Yang Ming Accused of Profiteering During Pandemic by Bed Bath & Beyond

      Ocean Transportation

    Digital Edition

    Scb august 2023 lg

    2023 100 Great Supply Chain Partners

    VIEW THE LATEST ISSUE

    Case Studies

    • JLL Finds Perfect Warehouse Location, Leading to $15M Grant for Startup

    • Robots Speed Fulfillment to Help Apparel Company Scale for Growth

    • New Revenue for Cloud-Based TMS that Embeds Orderful’s Modern EDI Platform

    • Convenience Store Client Maximizes Profit and Improves Customer Service

    • A Digitally Native Footwear Brand Finds Rapid Fulfillment

    Visit Our Sponsors

    Antuit Zebra Anvyl AutoStore
    BEUMER Group Blue Ridge Global Brother
    CHEP Cleo Coenterprise
    Data Capture E2open Enveyo
    Eva Air ForwardX Robotics Frayt
    GAINSystems Generix Geodis
    GEP Global Supply Chain Marketing Summit GreyOrange
    Here Holman Logistics Infor
    Inmar Kinaxis Lexis Nexis
    Locus Robotics Logility LogistiVIEW
    Lucas Systems MCA Connect MPO
    Old Dominion OneRail Overhaul
    PartnerLinQ (Visionet) Port of Virginia Ryder E-commerce by Whiplash
    Saddle Creek Logistics SAP Shyft
    Sourcemap SPS Commerce Tecsys
    TGW Systems Thomson Reuters Veho
    Verusen Walmart Workshop
    • More From SCB
      • Featured Content
      • Video Library
      • Think Tank Blog
      • SupplyChainBrain Podcast
      • Whitepapers
      • On-Demand Webinars
      • Upcoming Webinars
    • Digital Offerings
      • Digital Issue
      • Subscribe
      • Manage Your Subscription
      • Newsletters
    • Resources
      • Events Calendar
      • SCB's Great Supply Chain Partners
      • Supplier Directory
      • Case Study Showcase
      • Supply Chain Innovation Awards
      • 100 Great Partners Form
    • SCB Corporate
      • Advertise on SCB.COM
      • About Us
      • Privacy Policy
      • Contact Us
      • Data Sharing Opt-Out

    All content copyright ©2023 Keller International Publishing Corp All rights reserved. No reproduction, transmission or display is permitted without the written permissions of Keller International Publishing Corp

    Design, CMS, Hosting & Web Development :: ePublishing