Slow FMCG production lines are often caused not by machines or labor, but by the WIP boxes used every day. WIP boxes that do not match production needs can become hidden bottlenecks that many factory managers overlook.
The size, material, and design of WIP boxes all have a major impact on workflow efficiency in FMCG production lines. Choosing the right WIP box can therefore become a simple yet highly effective way to improve production output.
Common Problems Without the Right WIP Box System
Many FMCG factories still use improvised containers for storing semi-finished goods, ranging from wire baskets and cardboard boxes to regular plastic containers that were never designed for production lines.
As a result, small but preventable problems continue to occur, such as:
- Operators taking longer to move products between stations because the boxes are too heavy or not standardized in size
- Semi-finished products being easily contaminated because the boxes have no covers or surfaces that are difficult to clean
- Boxes wearing out quickly and needing frequent replacement, causing operational costs to keep increasing
- Unorganized product stacking that makes WIP stock checking more difficult.
Individually, these problems may seem minor. But across a full production shift, their impact on overall output can become significant.
PP Corrugated Plastic WIP Boxes as a Production Efficiency Solution
PP corrugated WIP boxes are becoming increasingly popular in the FMCG industry. This material offers characteristics that are difficult for other materials to match in production-line applications.
It is lightweight yet structurally strong. Its surface is smooth and non-absorbent, making it more hygienic than cardboard and easier to clean than metal.
These hollow plastic sheets can also be cut and formed according to the required dimensions, making them flexible for various production-line configurations.
Why Not Just Use Cardboard?
Cardboard may be inexpensive, but its lifespan is short, especially in humid production environments or areas exposed to liquids. Once wet, cardboard quickly loses its strength and can potentially contaminate products.
PP board, on the other hand, is water-resistant, resistant to dents, and reusable multiple times without significant quality degradation.
How WIP Boxes Improve FMCG Production Efficiency
WIP boxes designed specifically for production lines are part of a larger workflow system. When the size, material, and design fit operational needs, product movement between stations becomes faster, safer, and easier to monitor.
Some of the efficiency benefits of WIP boxes made from PP corrugated sheets include:
- Faster handling time: Lightweight boxes make it easier for operators to move products without additional handling equipment.
- Better hygiene. The non-porous hollow plastic surface is easy to wipe clean and does not trap product residue.
- Longer service life. The non-porous hollow plastic surface is easy to wipe clean and does not trap product residue.
- Stackable and space saving. These WIP boxes can be stacked securely to optimize production floor space.
Why Is PP Corrugated an Ideal Material?
Hollow polypropylene plastic boards are widely adopted by modern FMCG factories for WIP box applications because they are:
- Lightweight yet durable. The twin-wall corrugated structure provides strong structural support while remaining lighter than wood or solid plastic, allowing operators to move boxes more efficiently.
- Long-lasting and reusable. Unlike cardboard that may only survive one or two uses, polypropylene board WIP boxes can be reused repeatedly over long periods.
- Resistant to industrial environments. Polypropylene does not absorb water, is unaffected by humidity, and withstands exposure to mild chemicals commonly used in FMCG factory sanitation processes.
WIP Box Specifications Offered by ALVAboard
ALVAboard provides WIP boxes made from PP corrugated hollow plastic boards specifically designed for modern industrial operations. There are two main types available to match different production-line requirements:
WIP Box Type A
WIP Box Type A is ideal for industries requiring extra durability. This box is made from thick and sturdy hollow plastic sheets and comes equipped with:
- Velcro lid fasteners to keep contents secure during transport
- S-groove / S-Rib structural reinforcement for additional rigidity
- Reinforced hinges designed for repeated use in long production cycles
WIP Box Type B
WIP Box Type B is suitable for production lines that require tracking and product identification systems. This type includes:
- Strong and durable material for intensive production use
- Direct printing options on the box surface, including production calendars, batch codes, or other identifiers
- Custom sizes and colors according to industrial requirements
ALVAbox Type D
ALVAbox Type D features:
- A foldable and reusable design
- Higher durability compared to regular cardboard boxes
- Suitable for high-volume box requirements with more cost-efficient budgeting
Through its wide range of available products, including industrial container solutions for various operational needs, ALVAboard is ready to help you design the most efficient WIP box system for your factory’s specific production conditions.
Contact the ALVAboard team via WhatsApp at +6287793102838 today to discuss your factory’s WIP box requirements!
