The Innovative Future of Dangerous Goods Packaging

Advancements in material science are driving the development of next-gen hazmat packaging solutions.

By: John Glaser, Contributor

Plastic packaging kits provide a lighter and safer hazmat containment system than traditional metal secondary containers. Image courtesy of Labelmaster.

Every packaging engineer worth their salt knows that good packaging is about much more than just putting products in a box. It’s an essential part of business operations. From enhancing logistical efficiency to boosting customer satisfaction, sustainability, and safety, the importance of packaging can’t be overstated.

So, why hasn’t more progress been made to improve and innovate dangerous goods (DG) / hazardous materials (hazmat) packaging over the years?

Businesses shipping DG certainly have both the need and the desire for innovation. With new hazardous materials entering the supply chain, evolving regulations, and growing customer expectations, there is increasing demand for packaging that meets these expanded requirements.

In my conversations with DG teams, the chief reason for stagnation is very understandable: change can feel daunting — especially within the hazardous materials (hazmat) industry. After all, complex regulations and inherent risks are regularly associated with shipping and storing such goods.

What’s a dangerous goods pro to do?

THE INNOVATION GAP IN DG PACKAGING

One customer I spoke with not too long ago, who recently integrated new packaging into her company’s operations noted, “People stick to what they know,” admitting she had typically purchased the same old packaging, despite its deficiencies, without giving it much thought.

It wasn’t until someone showed her a better way to package and ship her hazmat that she considered alternatives.

Fortunately, this story has a happy ending.

Modern and proven DG packaging solutions are now available to improve safety, efficiency, and sustainability in the supply chain. However, to fully capitalize on these advancements, companies need to change their perspective on packaging.

The DG industry has traditionally been slow to embrace innovation. However, as the hazmat landscape evolves, so must the packaging solutions that protect these materials. Now is the time to challenge the norm and explore cutting-edge packaging technologies that can revolutionize supply chain operations.

BREAKING FREE FROM THE STATUS QUO

Despite these longstanding barriers to innovation, several trends and innovations are propelling progress in DG packaging.

Changes in market expectations, business priorities, and advancements in material science are driving the development of next-gen hazmat packaging solutions, including:

• Stronger Focus on Environmental Responsibility: Companies are increasingly prioritizing sustainable practices. A recent global study conducted by Labelmaster, IATA and Hazardous Cargo Bulletin showed that nearly half (47%) of DG professionals are very interested in sustainable packaging options over the next five years. Reusable and recyclable packaging helps reduce environmental impact without sacrificing performance or safety.
• Process Improvements to Boost Efficiency: Companies are eager to speed up supply chain processes. Modern packaging designs can help by reducing packing, filling, or shipping times. For instance, some new hazmat packaging solutions don’t require special fillers, labels, or training, and can be opened and closed without special tools, saving businesses time and money.
• New Strategies for Reducing Supply Chain Costs: Slimmer, lighter packaging can lower shipping expenses and optimize warehouse space. Certain innovative materials also provide sufficient protection on their own, eliminating the need for bulky fillers, gel packs, or heavy liners.
• Breakthroughs in Modern Packaging Technology: With the latest material science innovations, businesses can adopt new packaging with confidence, knowing that these materials meet high standards and undergo rigorous testing for safety and performance. These breakthroughs also allow businesses to reap the financial and operational benefits of adopting new innovations, even when shipping regulated, high risk goods.

Specialized hazmat packaging solutions minimize the risk of fires and chemical leaks when transporting electronics and lithium-ion batteries. Image courtesy of Labelmaster.

EXAMPLES OF INNOVATIVE PACKAGING SHAKING UP THE DG INDUSTRY

Consider this: many organizations still use overpack metal cans to ship hazardous materials — even though they could potentially leak, dent, rust, and are an absolute hassle to open and seal. I too have used many of these! Well, here’s some good news, a modern plastic overpack solution has been introduced that won’t dent or leak and can be reused multiple times. It even has a visual indicator when the closure is properly secured to give you confidence the shipment is safe for transit. It’s also smaller and lighter than the traditional cumbersome overpack making it less expensive to ship.

Another example is lithium battery packaging. Many businesses continue to use conventional cardboard boxes, which are flammable, to ship lithium batteries. Consequently, if the contents ignite (a scenario far too common in headlines these days), the box won’t just fail to contain the fire, it will fuel it. That’s why most shipments of lithium batteries and battery-powered devices require gels, heavy liners, or other fire-retardant fillers.

Fortunately, some modern packaging solutions are engineered specifically for storing and transporting lithium batteries and can provide a thermal barrier that mitigates the risk of fires by containing pressure, fire, gasses and projectiles without requiring use of gel packs, heavy liners or fillers. This makes warehousing and transporting lithium-related items safer, easier and more cost-effective.

TRANSFORM YOUR DG SUPPLY CHAIN WITH MODERN PACKAGING

Incorporating modern hazmat packaging into your supply chain offers valuable opportunities for improvement. To break free from old processes, one needs to think differently about packaging and its potential positive impact on your overall operations and business goals.

Asking “what if” is the first step in questioning existing processes and identifying new solutions that foster innovation and position your company as an industry leader. What financial benefits could new DG packaging bring? What operational efficiencies could be gained? How would this support our corporate sustainability goals? And what competitive disadvantages might result from not changing?

The next steps towards progress go hand-in-hand. Start by assessing your current packaging practices to identify areas for improvement in efficiency, safety, compliance, and sustainability. Partnering with an experienced hazmat shipping expert can be invaluable in this process. A knowledgeable DG partner understands the complexities of hazardous material shipping and the potential financial impact of upgraded packaging on your business. What’s more, the ideal packaging partner will not only recommend solutions but will also provide training and ongoing support to ensure a smooth transition, delivering confidence and compliance at every stage.

You deserve better DG packaging. And, it’s no longer out of reach. WMHS

John Glaser is director of packaging development at DGeo the Packaging Division at Labelmaster, a leading provider of products, services, and technology for the safe and compliant transport of dangerous goods. He focuses on developing next-generation solutions and building partnerships to offer the industry’s widest range of hazmat solutions. Visit: https://www.labelmaster.com/dgeo