Behind the Scenes: Packaging Area
Inside Komax
No access for unauthorized persons! Komax’s packaging area is a self-contained, strictly controlled security area. It differs from normal packaging plants in some respects. Many expect to find a customs-free area or consignment warehouse hiding behind the fences and gates, but that’s not the case. Discover what really goes on behind the doors – and why lives depend on working here accurately.
The fences and gates mean that Komax is a so-called "known consignor" and thus part of the secure air freight chain. The processes and employees in the packaging area and export area are thoroughly inspected and vetted for certification by the stringent Federal Office of Civil Aviation (BAZL). A lot depends on this certification.
Hans Graber, Head of Packaging and Shipping, explains: "As a known consignor, Komax is responsible for the security checks of each individual shipment. We guarantee that no dangerous goods will enter the air cargo. This is a great responsibility because only about a third of the load of a passenger aircraft consists of passenger luggage; the rest is commercial freight. Just one single loose button cell battery would have the potential to blow a hole in the hull of an aircraft. This is why there is strict access control throughout the entire packaging area."
Around 20 percent of Komax’s machines and 90 percent of its spare parts are air freight. These deliveries go directly to the plane at the airport without any further checks, because Komax is certified as a “known consignor” and can therefore guarantee safety. This saves the customer money because the usual time-consuming checks in the freight terminal are no longer necessary.
The goods also arrive much faster. Kevin Brijan, Packaging Area Team Leader, explains: "If the conventional security checks are carried out at the airport, shipments often remain there for three to four days until the security check is carried out. Thanks to our license, when we receive an order today, the goods are loaded onto the plane by tomorrow and reach the customer as quickly as possible."
Komax ships hundreds of packaging units every week, be it machines, spare parts or consumables. The size of the packages varies from an envelope to crates the size of garden sheds.
In the machine packaging department, the processes are optimized so that an average-sized Komax machine is ready for delivery in just 70 minutes. For each machine type, there are precise specifications as to how each component is to be packaged and who in the team is responsible for which tasks. This guarantees the highest standards of quality and safety.
Our own innovations also make it easier to work safely. A lifting device developed by Komax safely lifts even the largest machines so that pallets can be easily and precisely placed beneath them.
“This is much more than just a wooden box; it is high-performance packaging optimized down to the finest detail and intensively tested by us,” explains Milan Schmidt (left), Deputy Packaging Area Supervisor. "Each machine must withstand a 60 cm drop without damage. The so-called floating packaging with frequency damping also prevents screws from working loose as a result of vibration during transport."
Komax has been committed to providing sustainable packaging for many years. Only three recyclable materials are used: wood – wherever possible from Swiss production –, polyethylene and paper. The crate components are delivered just-in-time by a regional producer and are stored in the warehouse, ready for use.
Every week, tons of materials leave the spare parts dispatch area for destinations all over the world. This department also complies with the strict security concept. Here, the parts are delivered from various warehouses, checked, consolidated, compressed ready for dispatch, and then sent to the Export area.
“Each individual Komax product is photographed here and can be called up via its article number in our ordering system,” explains Logistics Specialist Julia Gabriel. "This is very helpful for our customers in everyday operations: They can literally see at a glance if they are ordering the right part."
One part at a time, one order at a time: Serial packaging ensures maximum safety and quality. Employees assemble the products delivered from the automated small parts warehouse at workstations that they can design and set up according to their needs.
More than 350 high-quality articles are packaged with an attractive design. With so-called "brand packaging", customers can be assured that they receive original parts from unopened packaging. Precise unpacking instructions also result in significantly fewer returns.
Skin packaging perfectly showcases the products and protects them. It also provides the customer with an initial opening and original parts warranty. Komax has developed a process to be able to produce the carrier box cost-effectively, from a batch size of just one, and this has led to a nomination for a packaging award.
The “regulated agent” – a certified chauffeur – is also part of the secure air freight chain. This agent must register at the security gate, show identification, and present an employer contract and a detailed order confirmation in order to be able to collect the goods for transport.
"Komax is committed to Industry 4.0 – from production to the customer," says Hans Graber, Head of Packaging and Shipping. “We are proud to add the finishing touch to our high-quality machines and spare parts with smart packaging before they embark on their journey to our customers around the world.”
Contact
Hans Graber has been with Komax since 1992 and is responsible for goods dispatch and packaging development.
