Freqeuently Asked Questions

What does CORBI do for its customers?

Can you describe the CORBI 360° Total Dunnage Management™ process from the perspective of a container manufacturer?

Can you describe the CORBI 360° Total Dunnage Management™ process from the perspective of a filler?

Can you describe the CORBI 360° Total Dunnage Management™ process as packaging materials pass through CORBI service centers?

Can you detail the overall advantages of a dunnage management system?

Can you describe the concept of pooling as it is gaining in popularity?

Why is it important to use plastic dunnage and maintain its industrial sterility?

What benefits can customers expect when they use plastic dunnage as opposed to paper?

How important is the cleanliness of secondary packaging to ensure avoidance of contamination for the final food/beverage product?

Can you explain the CORBI cleaning process?

What does a successful business model look like for a customer when they do business with CORBI?

How does a company most efficiently make the switch to plastic dunnage?

How does CORBI integrate its dunnage management methods for a new customer?

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Q: What does CORBI do for its customers?

  • CORBI is a manufacturer and services provider for reusable plastic transport packaging materials (commonly referred to as dunnage) serving the rigid container industries.
  • CORBI’s reusable, sanitary and recyclable dunnage (plastic and co-extruded separator sheets, sealed corrugated plastic layer pads, pallets and top frames) is all manufactured to meet the specific needs of a customer’s product, application and business.
  • Using the latest extrusion technology, CORBI manufactures its reusable plastics for varying thickness, dimension, color and branding.

More specifically, CORBI provides a dual focus that is unique for the American customer base.

  • By combining its plastic dunnage with its proven and comprehensive management process, CORBI ensures asset utilization and provides a series of benefits for the user.
  • CORBI drives value through the supply chain with a systematic management of reusable plastic dunnage as it goes from container manufacturer to filler to service centers – and back again in a continuous loop. CORBI calls this process CORBI 360° Total Dunnage Management™.
  • CORBI utilizes its proprietary software to track, ship, distribute, recover, sort, store, inspect, clean, repair and replenish reusable plastic dunnage faster, better, safer and more cost-effectively than the industry has done before.
  • CORBI’s dedicated staff and systems keep constant watch over material movements and customer requirements to actively manage its materials in a national common pool.
  • By using a collective supply of dunnage in a common pool, customers will benefit from improved cost structures, asset visibility and utilization.

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Q: Can you describe the CORBI 360° Total Dunnage Management™ process from the perspective of a container manufacturer?

CORBI supplies packaging when, where and in the quantities needed. CORBI monitors customer shipments and return requirements so that container manufacturers get:

  • Correct kind and quantity of dunnage the moment it is needed, avoiding shortages, excess and the need for large amounts of storage space.
  • High-level of material-to-material performance for operational consistency to ensure a plant’s processes operate continuously and keep products safe.
  • Industrially sterile dunnage that safeguards against compromising product integrity.
  • Lower cost structure due to the continuous reusability of plastic dunnage.
  • Active management to improve utilization, visibility and accountability.

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Q: Can you describe the CORBI 360° Total Dunnage Management™ process from the perspective of a filler?

CORBI manages stock balances and arranges stock pick-ups so that fillers get:

  • Properly secured and undamaged food and beverage containers.
  • Consistently sanitary transport materials to better protect food and beverage containers and keep filler warehouse free from contaminants.
  • Accurate reporting for greater packaging visibility.
  • High-level of performance from transport materials maintaining dimensional and performance requirements for decreased handling damage and depalletizer downtime.

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Q: Can you describe the CORBI 360° Total Dunnage Management™ process as packaging materials pass through CORBI service centers?

CORBI has 13 service centers strategically located to improve logistics for its dunnage pool and cut travel distances as dunnage passes from container manufacturer to filler and back again. The
service centers are equipped with state-of-the-art processing options designed to ensure that products are safe during transport and storage. CORBI’s service centers provide:

  • State-of-the-art dunnage cleaning technology that adheres to food-grade and HACCP requirements.
  • Established and documented processes that eliminate the risk of contaminants as well as the growth and spread of bacteria.
  • Material storage in a food-grade environment.
  • Quick asset service turnaround.
  • Consistent asset inspection to ensure continuing quality and a high-level of reusability.
  • Highly accurate dunnage accounting to ensure asset utilization and recovery.
  • Services that are proven to keep dunnage working efficiently, longer than expected and exponentially longer than the short life span of paper and wood dunnage.

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Q: Can you detail the overall advantages of a dunnage management system?

The vast majority of the cost of reusable plastic dunnage is not the initial purchase price but the cost of managing and handling the dunnage during its life. CORBI’s core competency is seen in its dunnage management process, developed through years of experience in Europe and the US. The process maximizes the value of the dunnage by lowering the costs of handling and managing the dunnage pool while maintaining quality and service.

CORBI 360° Total Dunnage Management™ improves process performance at several levels – operationally, financially and environmentally.

Operationally:

  • High-performance of plastic dunnage means reduced plant downtime
  • Active management of third party service providers
  • National services provider
  • Optimized freight shipment
  • Seamless rebalancing of supply
  • Consistent performance of plastic dunnage reducing workplace hazards
  • Full vertical storage utilization

Financially:

  • Reusability eliminates internal capital purchase requirements
  • Efficient management, pooling and reusability removes material conversion and switching justification hurdles
  • Reducing the amount of consumed materials (the repurchasing of depletable paper and wood dunnage) trims material replacement expenses
  • Eliminates disposal expenses (of paper and wood dunnage)
  • Lowers per trip costs

Environmentally/Sustainability:

  • 100 percent of CORBI materials and reused and recycled into new dunnage
  • Reusability eliminates paper and wood waste
  • Consistently defined and applied services criteria increases material life
  • Using plastic reduces plant dust and debris that accumulates with paper and wood dunnage
  • Eliminates organic bacterial growth
  • Expertly managed material network decreases transportation travel time, distance and consumption

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Q: Can you describe the concept of pooling as it is gaining in popularity?

  • In Europe, CORBI’s parent companies Cartonplast and Karton established a sheet pool in 1988.
  • They have more than 25 million sheets in service and manage more than 100 million sheet trips per year.
  • Those companies are a fully integrated supply chain partner for 40 container plants supplying 4,500 fillers. They also operate nine cleaning facilities.
  • In North America, CORBI established a sheet pool in 1999.
  • Today, they have more than 10 million sheets in service with three cleaning facilities and 13 service centers to manage more than 75 million sheet and three million pallet and top frame trips per year.
  • CORBI is an integrated supply chain partner for 35 high-quality container plants supplying 200 quality-conscious fillers.
  • CORBI dunnage management pool extends throughout North America.

On Jan., 2009, CORBI completed an agreement with DS Container to join CORBI’s dunnage management pool in April 2009.

  • DS Containers will inject annual volumes of 125,000 pallets and 125,000 top frames and will share all dunnage with the CORBI pool.
  • They will complete their switch to plastic divider sheets in mid-2009 to further reduce their dunnage cost structure.

CORBI already manages a comprehensive dunnage management program for Rexam in America;

  • Managing 58 million sheet trips per year and 2.8 million frame and pallet trips per year.
  • CORBI began managing services for Rexam in February 2006 in Chicago and St. Paul and completed full conversion of all Rexam plants to CORBI’s fully managed system in March of 2007.
  • To better serve Rexam, CORBI established a presence nearby each Rexam plant to service all of their reusable packaging needs.

CORBI manages dunnage as it travels through the industry supply chain in a national common pool.

  • CORBI’s specialization in managing the complexities of transporting and tracking a pool of packaging products (dunnage) enables customers to reap the full operational, financial and environmental benefits of reusable plastic dunnage.
  • When dunnage is rented, pooling can eliminate the initial investment of purchasing packaging products by offering products on a per-trip basis.
  • Additional cost savings are injected into the model when multiple users share a common pool of packaging materials.
  • Whether the packaging is customer-owned or rented, CORBI manages pools of product to ensure supply chain ease for its customers.
  • The constant availability of pooled products reduces cost and eliminates system downtime due to packaging shortages and reduces storage requirements.

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Q: Why is it important to use plastic dunnage and maintain its industrial sterility?

  • Using plastic dunnage is important because paper and wood dunnage cannot be cleaned and is not consistent in dimension, weight or performance which causes equipment stoppages, damaged product and added costs.
  • As an organic material, paper and wood creates a breeding ground for the growth and potential spread of bacteria and mold.
  • Maintaining industrial sterile dunnage provides protection against the risk of contaminating containers and product.
  • CORBI’s plastic dunnage is routinely cleaned to match a level of industrial sterility and meet strict cleanliness requirements to keep products safe and free of various contaminants.

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Q: What benefits can customers expect when they use plastic dunnage as opposed to paper?

  • Paper and wood dunnage causes instability, breakage, machine downtime and lost revenue. It tears, gets wet, expands, contracts, creates dust, debris, clutter and waste and constantly needs to be repurchased and disposed of.
  • Plastic dunnage safeguards from a number of concerns associated with using paper and wood dunnage.
  • Plastic has been proven to be the more efficient material. It has a higher-level of product-to-product consistency, integrity, performance, reusability, industrial sterility and durability.
  • CORBI’s refined dunnage management process allows customers to reap the full operational, financial and environmental benefits of using plastic dunnage and paper and wood dunnage.

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Q: How important is the cleanliness of secondary packaging to ensure avoidance of contamination for the final food/beverage product?

  • Secondary packaging (layer pads, divider sheets, pallets, etc) is vital as it moves through the logistics chain as an accompaniment to all containers – from container manufacturers to fillers and eventually to the customers.
  • If the cleanliness is compromised – as can easily happen with organic paper and wood dunnage – bacteria and other contaminants can easily pollute the final product.
  • As a non-organic material, plastic dunnage eliminates the breeding ground thus disabling the risk of bacteria growth, and it can be cleaned to adhere to strict food-grade and HACCP standards.
  • CORBI’s plastic dunnage maintains a level of industrial sterility, i.e. as clean as the cleanest spot in a plant, to meet those standards.
  • CORBI’s plastic dunnage is cleaned as it passes through CORBI’s service centers to ensure that container manufacturers and fillers have a sterile supply of dunnage.

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Q: Can you explain the CORBI cleaning process?

  • CORBI leads the industry in the cleaning of corrugated and solid sheets using wet and MicroDry™ technologies that originated from the parent company’s European operations.
  • These technologies allow CORBI’s plastic dunnage to meet food-grade quality that conforms to HACCP principles.
  • While CORBI’s plastic dunnage is used as secondary packaging, CORBI’s cleaning process is designed to adhere to the higher cleanliness specifications for primary packaging as it is used in food and beverage applications.
  • The cleaning procedure incorporates the use of proprietary equipment. CORBI’s “wet cleaning” process offers commercial sterilization and is the most effective process against a broad spectrum of impurities.
  • Once cleaned, the dunnage becomes “industrially sterile” and is cleaner than the product placed on it. The MicroDry cleaning process is effective against superficial dust and contaminants, enabling an industrially sterile surface.

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Q: What does a successful business model look like for a customer when they do business with CORBI?

Customers will benefit from:

  • Absence of worry about dunnage
  • No staff managing dunnage
  • No capital justifications for dunnage
  • Reduced storage costs for dunnage
  • Lower per use dunnage costs
  • Focus on core competency is increased

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Q: How does a company most efficiently make the switch to plastic dunnage?

To smoothly make the switch to using plastic dunnage, companies may:

  • Enlist a company like CORBI, with experience managing the transition for numerous customers, to assist with planning and implementing the transition.
  • Working with CORBI, analyze dunnage requirements to plan the transition - including plant and customer handling requirements.
  • Analyze dunnage requirements for daily and seasonal production requirements, inventory levels throughout the year, customer turnaround of dunnage, dunnage in transit requirements, etc.
  • Plan the transition at plants and customer sites to include equipment compatibility issues, operator and forklift training to minimize damage and loss and document controls to maintain good accountability.

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Q: How does CORBI integrate its dunnage management methods for a new customer?

CORBI has set-up full dunnage management programs for a number of customers already. CORBI is skilled at leading their customers to efficiently take advantage of CORBI 360° Total Dunnage Management™ by:

  • Training operators and warehouse personnel in best practices in using, loading, unloading and storage of reusable dunnage.
  • Training operators on the use and importance of documentation and control of dunnage use and movement.
  • Adapting dunnage configurations to individual plant and filler requirements to assure flawless operations.
  • Scheduling deliveries, onsite inventory levels and recovery procedures to ensure compatibility with current operations.
  • Clearly identifying contact points for plants and customers to address issues as they arise.

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