For example, threads that won’t withstand water or sunlight aren’t a good choice for sewn fabric dunnage that’s stored outdoors. Threads that don’t support cleaning can muddy your true costs, too. Choosing the right rack bag thread is just one of many design considerations, but packaging engineers need to pay close attention to material selection to avoid problems like pockets that sag and seams that tear.

Thread Types and Coatings

Threads for sewn fabric dunnage can be made of Kevlar, nylon, polyester, or cotton.

• Kevlar thread is significantly stronger than nylon or polyester.
• Nylon thread is fine for general-purpose use, but it can’t withstand prolonged exposure to ultraviolet (UV) light from the sun.
• Polyester thread looks like nylon, but has better sunlight and moisture resistance.
• Cotton thread is soft and durable, but it’s not as strong as polyester. Plus, cotton thread will rot in the elements.

Thread coatings can increase your reusable packaging costs, but these substances impart properties that can improve thread life and performance. For example, polyester and nylon threads that are bonded have a smooth, protective coating that strengthens the thread and makes it less abrasive. To reduce friction during winding, polyester threads can be treated with a lubricant.

Thread Colors and Age

Most rack back threads are either white or black in color. These colors tend to differ in age.

• White threads tend to be newer because they’re sold as they are, or dyed different colors to meet customer demand.
• Black threads tend to be older because some thread manufacturers re-dye their old, unsold colored thread so that it’s black.

Dying older threads black saves the thread supplier money, but may cost the packaging user in the long run. Unlike wine, rack bag threads don’t improve with age. Rather, older threads tend to be weaker.

Reusable Packaging Costs and Quality Sewn Fabric Dunnage

Hold-True, a Made in the USA manufacturer of reusable packaging, can help you to select the right threads for sewn fabric dunnage. For example, the threads we recommend are treated with a UV inhibitor to reduce damage from sunlight and prevent fading or spotting in the thread color. Importantly, we only buy thread from supplier who don’t re-dye old, colored thread. High-quality thread may cost more, but rack bags that last save you money in the long run.

To learn more about us and how we can help you, contact Hold-True.

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Rack Bag Design for Sewn, Reusable Fabric Dunnage

Rack bag design isn’t just about pocket size or material selection. It’s not just about computer aided design (CAD) software either.

Fabric Dunnage: How Dirty Rack Bags Muddy Your Costs

Fabric dunnage that’s cheaper may seem like a bargain, but there’s more to consider than just the purchase price. Dirty rack bags can muddy your true costs.

Work-in-Process Bags: Why the Pockets Sag on WIP Bags

Work-in-process bags are used for kitting and sequencing parts for assembly-line production. Learn how to design better pockets for WIP bags.

Three Ways to Cut Your Sewn Fabric Dunnage Costs

Sewn fabric dunnage costs are about more than just the purchase price of rack bags. Learn how to reduce your packaging costs and ensure rack bag ROI.

Fabric Dunnage Suppliers: Cost Isn’t the Only Consideration

Cost isn’t the only consideration with fabric dunnage suppliers. Hold-True explains what sourcing managers need to look for in reusable packaging partner.

Made in USA Fabric Dunnage

Made in USA fabric dunnage from Hold-True is about American know-how and a commitment to meeting your needs.

Sewn Fabric Dunnage: Four Reasons Why Rack Bag Seams Fail

Sewn fabric dunnage that fails can cost you time and money. Rack bag seams tear for many reasons, but there are four that relate to threads and stitching.

Fabric Dunnage Costs and Thread Selection

Fabric dunnage costs and thread selection are related. Lower-cost threads may seem like a bargain, but using a thread that’s too thin (and too weak) can cause rack bag seams to fail.

How to Design Fabric-Resistant Fabric Dunnage

Designing puncture-resistant fabric dunnage means following some basic guidelines for protective panels, structural members, bonding, and fabric. Learn what they are.

Fabric Dunnage Materials: Laminated Fabrics vs. Coated Fabrics

Laminated fabrics for sewn fabric dunnage are composite materials with a layered structure. Two of more materials are bonded together to impart benefits.

Fabric Dunnage Materials: Coated Fabrics vs. Laminated Fabrics

Coated fabrics are fabric dunnage materials that consist of a woven or non-woven cloth with a specialized coating. Woven coated fabrics are in rack bags.

Brushed Tricot Fabric for Reusable Packaging

Brushed tricot fabric for reusable packaging is a soft liner-material that can be used with Class A surfaces such as chrome parts or faux wood panels.

How to Choose Plastic Doors for Fabric Dunnage

Plastic doors for fabric dunnage need to protect parts and withstand the environment. Here’s what packaging engineers need to consider.

Custom Tyvek for Reusable Packaging Strengthens Fabric Dunnage

Custom Tyvek for reusable packaging (sewn fabric dunnage) combines the advantages of Tyvek with a reinforcing scrim and easy-to-clean surface.

Rack Bag ROI: Calculate Your True Dunnage Costs

What are your dunnage costs? If you don’t know what you’re really paying for sewn fabric dunnage, you might be spending too much on packaging.

Automotive Rack Bags: Advantages and Applications

Automotive rack bags provide important advantages over automated dunnage that’s made of corrugated cardboard, plastic, and all metal.

How to Get the Automotive Dunnage That You Need

Do you enjoy a good story? Then kick back, relax, and learn how Patrick the packaging engineer got the automotive dunnage that he needed.

Velcro Straps for Sewn Fabric Dunnage

Velcro straps are used to secure loads in sewn fabric dunnage. Velcro is easier to open and close than cams, buckles, zippers, or other hardware.

Sewn Fabric Dunnage: Seven Solutions to Packaging Problems

The benefits of sewn fabric dunnage are clear. Yet there are also seven challenges that require expert packaging solutions.

Reusable Packaging Design: Seven Common Challenges

With reusable packaging design, there are seven common challenges to avoid. Do you know they are? Read this article to find out.

Capital Planning for Returnable Dunnage

Capital planning for returnable dunnage can help you reduce your packaging costs over the long haul. Hold-True explains what capital planners need to know.

Reusable Packaging: A Buyer’s Guide for Capital Planners

Get the buyer’s guide that capital planners need for reusable packaging. Learn which questions to ask and which assumptions to question.

Reusable Packaging: How CFOs Make Better Budget Decisions

With reusable packaging, chief financial officers (CFOs) need to meet three challenges: changing the mindset, filling the vacuum, finding the right partner.

Returnable Packaging Basics: Digital vs. Analog Design

For packaging engineers, a sound knowledge of returnable packaging basics begins with digital vs. analog design. How well do you understand the difference?

Class A Surfaces and Reusable Packaging Materials

Class A surfaces need to be handled with care. To prevent scratching, a reusable packaging material like brushed tricot fabric is used.

What Will Be the Top Reusable Packaging Posts of 2018?

The new year isn’t even here yet, but you’ll find the top reusable packaging posts of 2018 here at Hold-True. In the meantime, contact us for more information about sewn fabric dunnage for the automotive, heavy truck, power sports, and aerospace industries.

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At some OEMs, capital planners are still budgeting for rack bags that last only 24 months. Yet higher-quality fabric dunnage can last up to 72 or even 80 months. This longer-lasting reusable packaging costs more up-front, but provides a stronger ROI over the long-term. Maintenance and cleaning costs are less, and there are fewer spares to carry. Plus, by treating packaging as a capital expense (CAPEX) instead of an operational expense (OPEX), you can spread-out costs over several years.

Reusable Packaging and CFO Decision Making

For chief financial officers (CFOs) and other decisionmakers, there are three aspects to making better budget decisions about reusable packaging:

• Changing the mindset
• Filling the vacuum
• Finding the right partner

Let’s examine each of these challenges.

Changing the Mindset

Decisions about packaging budgets aren’t just complicated by short time horizons. Some financial personnel may be unable or unwilling to move dollars around. In large organizations especially, different groups own different budgets. Consequently, some employees may oppose changes even when operational expenses are larger than the capital investments that would be required to reduce them. A $75K CAPEX could eliminate a million-dollar expense, but can a capital planner make that happen?

Filling the Vacuum

Capital planners and other financial personnel want to do what’s best for the company, of course, but they may not have a way to resolve issues that are beyond their span of control. That’s where smart CFOs step-in and make decisions that benefit the entire organization. In other words, these decisionmakers don’t let the usual corporate budgeting practices get in the way of a packaging budget that really works. Instead, these CFOs look at how products are expensed and the organization’s true costs.

Finding the Right Partner

Are you the CFO for an OEM in the automotive, heavy truck, power sports, or aerospace industry? Would you like to learn more about how sewn fabric dunnage can help your organization to reduce costs and promote supply chain efficiency? Hold-True, a Made in the USA manufacturer of sewn fabric dunnage, is ready to help. To get started, contact us.

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When engineering departments submit their budget requests, however, some finance departments don’t ask enough questions – or question some basic assumptions. That’s where capital planners can add value through due diligence. By asking the right questions, capital planners can discover the true costs of new and replacement dunnage. This supports greater accuracy in budgeting and can lead to reduced costs over the long term. There are several basic areas that planners need to consider.

Longevity

What is the expected life of the sewn fabric dunnage that your packaging engineers say that they need? If engineering asks for packaging that lasts for 24 months, find out how much it would cost to buy dunnage that lasts for 72 or even 80 months. You’ll pay more up-front, but what if your rack bags last 100% longer? Eventually, you’ll cut your capital expenses in half.

Reliability 

Are your packaging engineers asking for rack bags that are reliable enough? Lower-quality packaging can cost less, but you’ll have to carry a larger number of spares. Plus, if sewn fabric dunnage fails in the field, what’s the cost of downtime? After all, assemblers can’t do their jobs if they don’t have the parts they need. Inadequate protection for Class A surfaces can also lead to damaged parts and lost dollars.

Maintenance and Cleaning

What are the maintenance and cleaning costs for the reusable packaging that your engineers want to buy? Recyclable packaging that’s made of lower-quality materials costs less, but some fabrics and plastics won’t withstand water, sunlight, or outdoor temperatures for very long. Dunnage that gets wet and dirty can also become moldy. Rack bags that aren’t ruined can be repaired or cleaned, but there’s always a cost.

Disposal and Replacement 

How much will it cost to dispose of and replace the rack bags that your engineers want? Remember that disposal costs include breakdown, hauling, and landfilling. Packaging that’s built to last for 24 months may not experience major price hikes, but there are no guarantee that you’ll pay the same amount in two years. Without price stability, future capital planning could be even more challenging.

Vendor Selection for Capital Planners

Finally, which fabric dunnage supplier will provide your organization’s reusable packaging? Unless the selected vendor is a value-added manufacturer, your engineers may not get the design assistance and help with material selection that they need. To learn more about the questions that capital planners need to ask – and which supplier of sewn fabric dunnage can help – contact Hold-True.

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What Are Your True Costs?

By evaluating the true costs of returnable packaging, capital planners can save their organizations money over the long haul. Better packaging designs can be more expense, but that isn’t always the case. A longer-lasting rack bag may cost more up-front, but reductions in cleaning and maintenance costs can reduce total expenses. Returnable packaging lasts longer – often twice as long. By budgeting for dunnage that’s more reliable, you can reduce the number of spare rack bags you’ll need to carry.

If you’re a capital planner, make sure to ask the engineer who submits the budget request how long the returnable dunnage is expected to last. Then, question the assumption that reusable packaging can’t last longer to provide greater value. If the engineer expects the dunnage to last for 24 months, ask about the possibility of a 72 or 80-month period instead. In other words, question the assumption that a two-year lifespan is as good as it gets.

Hold a Different Viewpoint

Focusing on total costs instead of purchase price requires a different way of thinking, but organizations that take the long view see greater benefits. For example, let’s say that you invest in better-quality dunnage over a multi-year period. You pay 20% more up-front, but your rack bags last 100% longer. Eventually, you cut your capital expense in half. At a large organization like a heavy truck manufacturer, capital planning like this could reduce expenses from $4 million to $2 million.

Every organization is different, of course, but even smaller companies can realize a cost savings by looking at more than just purchase price. You may not save a ton of amount of money right away, but proper planning isn’t about taking a short-term view. Over time, however, you’ll benefit from the “multiplier effect” of budgeting for rack bags that last significantly longer. By partnering with the right vendor, your entire organization can benefit from your insistence on taking a longer view.

Ask Hold-True about Capital Planning for Returnable Dunnage

Hold-True is a Made in the USA manufacturable of sewn fabric dunnage, a type of returnable packaging that’s especially cost-effective. From analog design to help with material selection, we back every product with quality manufacturing. To learn more about our Mansfield, Ohio company and how we support the automotive, aerospace, heavy truck, and power sports industries, contact us on-line.

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Purchase Price and Dunnage Costs

Vendor A offers you 500 rack bags at $500 each. That’s a quarter-million dollar ($250,000) investment. You think you’re getting a good deal because Vendor B offered you rack bags at $750 each for a total of $375,000 across your fleet. All sewn fabric dunnage is the same, right? By paying Vendor A’s $500 per bag instead of Vendor B’s $750 per bag, you can save the company $125,000 up front. The Purchasing Department thinks you’re a hero and you’re ready to ask your boss for a raise.

There’s a problem, however. It’s not a small one either. Vendor A’s fabric dunnage will last two years if you’re lucky. Vendor B’s rack bags will last a solid four years. Over the course of a four-year period then, you’ll need to buy twice as many rack bags from Vendor A as you would from Vendor B. That’s when you realize the Finance Department will call you a zero instead of a hero if you don’t forecast your costs.

If you buy fabric dunnage from Vendor A, the lower unit price ($500) will require a higher expenditure overall ($500,000 for 1000 rack bags). In other words, Vendor A’s $250,000 quote looks like a savings, but it’s really 50% less than what you’d need to spend. When you compare Vendor A’s $500,000 to Vendor B’s $375,000, you nearly fall out of your chair. Choosing Vendor A won’t save you $125,000. Instead, you’ll pay Vendor A $125,000 more!

Maintenance and Repairs

The numbers in this example are simple, but don’t discount them because the math isn’t complex. If you want to find fault, however, it’s that the comparison doesn’t account for some additional costs. For each rack bag that fails, let’s say that your company pays $100 in labor to change-out the bag. This means that during a four-year period, you’d spend $50,000 to change-out all 500 of the rack bags that you bought from Vendor A.

That’s not the only problem. Vendor A’s rack bags don’t just fail because of lower-quality materials or manufacturing defects. Part of the reason the dunnage doesn’t last is because of design. Vendor A received CAD files from your packaging designer and manufactured the rack bags exactly as specified. Vendor B looked at the CAD files, but also tested your parts with a prototype bag. After loading and unloading some sharp parts, Vendor B recommended design changes that increased puncture-resistance.

Maybe all of Vendor A’s rack bags aren’t punctured by sharp parts, but you’ll still need to pay for some repairs. There’s another cost to consider, too. If Vendor A’s dunnage doesn’t protect high-value parts from scratching, you’ll have to pay for replacements. There could also be idle time on the assembly line if workers don’t have the parts they need to get the job done. Labor and material costs vary, but the bottom line is that Vendor A is costing you more.

Control Dunnage Costs with Hold-True

Hold-True is a Made in the USA manufacturer of sewn fabric dunnage that uses high-quality materials and expert manufacturing to give you the rack bags that you really need. We don’t just look at your CAD files either. Instead, through what we call “analog design”, Hold-True tests your parts in prototype bags under real-world conditions. Our rack bags may cost more up-front, but they deliver greater ROI because they last longer. To learn more, contact us.

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For example, a thread that won’t withstand water isn’t a good choice for reusable packaging that’s kept outdoors in the rain. Threads that won’t support rack bag cleaning can muddy your true costs, too. Choosing the right thread is just one of many design considerations, but rack bag buyers need to pay close attention to material selection to avoid problems like pockets that sag on WIP bags.

Hold-True, a Made in the USA manufacturer of rack bags, can help you to select the right materials for your returnable packaging. Importantly, we also create sewn fabric solutions that meet your specific needs. Here at our manufacturing center in Mansfield, Ohio, we’re ready to answer your questions about thread fibers, coatings, colors, and manufacturers. It’s just one of the ways that we add value.

Thread Fibers and Thread Coatings

Threads for sewn fabric dunnage can be made of Kevlar, nylon, polyester, cotton, or cotton blends. Kevlar thread is significantly stronger than nylon or polyester. Nylon thread is fine for general-purpose use, but it can’t withstand prolonged exposure to ultraviolet (UV) light from the sun. Polyester thread looks like nylon, but has better sunlight and moisture resistance.

Cotton thread is soft and durable, but it’s not as strong as polyester. Plus, cotton thread will rot in the elements. To maximize your fabric dunnage ROI, Hold-True uses thread with a UV inhibitor to reduce damage from sunlight when your rack bags are outside. UV inhibitors also prevent fading or spotting in the thread color.

Thread coatings can increase your sewn fabric dunnage costs, but these substances impart properties that can improve thread life and performance. For example, polyester and nylon threads that are bonded have a smooth, protective coating that strengthens the thread and makes it less abrasive. To reduce friction during winding, polyester threads are treated with a lubricant.

Thread Color and Thread Manufacturers

Most rack back threads are either white or black. White threads tend to be newer because they’re sold as they are, or dyed different colors to meet customer demand. Black threads tend to be older because some thread manufacturers re-dye their old, unsold colored thread so that it’s black. This business practice saves the thread supplier money, but it can cost the rack bag designer in the long run.

Unlike wine, rack bag threads don’t improve with age. Rather, older threads tend to be weaker. That’s why Hold-True only buys thread from suppliers who don’t re-dye old colored thread so that it’s black. Thread from the best suppliers costs more, but dunnage that lasts longer saves you money in the long run. Remember: if you’re not buying the best black thread, you’re better off buying white thread instead.

To avoid problems caused by improper thread selection, it pays to choose the right fabric dunnage supplier.  At Hold-True, we add value to your sewn fabric dunnage through design assistance, help with material selection, and Made in the USA manufacturing. For the highest quality, our thread comes from Europe or is Made in America.

To learn more about fabric dunnage costs and thread selection, please contact us.

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Cutting your sewn fabric dunnage costs is a three-step process. First, you’ll need to know what those costs really are. Second, you’ll need to choose the right rack bag vendor. Finally, it’s essential to leverage the supplier’s capabilities to meet your specific challenges.

Know Your Sewn Fabric Dunnage Costs

Reducing your fabric dunnage costs starts with understanding them. Every company is different, but there are some common points to consider. Sewn fabric dunnage doesn’t just cost you money when you buy it. Reusable packaging requires cleaning and maintenance. Removing mold and repairing shelving takes time. Plus, when you remove a parts bag from service, you’ll need to introduce a replacement.

What are your rack bag cleaning and maintenance costs? What are your carrying costs for the sewn fabric dunnage that you hold in reserve? When you order replacement rack backs, are the minimum order quantities (MOQs) so high that you buy larger lot sizes than you really need? Choosing the right rack bag supplier can help you to reduce costs, but what should you look for in a vendor?

Select the Right Rack Bag Vendor

Hold-True doesn’t make the world’s cheapest rack bags. Instead, we supply sewn fabric dunnage that provides you with a real return on investment (ROI). When you source your sewn fabric dunnage from us, you’ll get reusable packaging that lasts longer and supports all of your business requirements. That includes packaging and shipping as well as kitting and assembly.

The value-added services that Hold-True provides means you’ll get the rack bags that you really need. You can order small-lot quantities, receive and review prototypes that you can hold in your hands, and apply our technical knowledge and application expertise to your specific challenges. Plus, all of our sewn fabric dunnage is proudly Made in the USA to the highest quality standards.

Leverage the Supplier’s Capabilities

When you choose Hold-True, we apply what we know about rack bag design for sewn, reusable fabric dunnage. During the material selection process, we help you to choose fabric and shelving materials that support cost-effective cleaning and maintenance. Are you ready to tell us about your challenges and the value-added services that you need? Contact us here at our headquarters in Mansfield, Ohio (USA).

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Buying fabric dunnage that’s cheaper may seem like a good idea, but there’s more to consider than just the purchase price. How does your organization store and use rack bags? For that matter, how well do you understand your true dunnage costs? To get a clean, clear picture of what fabric dunnage is really costing you, it’s time to roll up your sleeves and get dirty. No, you don’t need to load or unload the parts yourself. But you do need to understand what’s happening to your rack bags and the parts that they hold.

Fabric Dunnage: Parts Damage and Dunnage Cleaning

Fabric dunnage gets dirty. For as much as 50% of a rack bag’s life, this returnable, reusable packaging is stored outdoors. These dunnage bags are usually empty, but that doesn’t stop the wind from blowing or the rain from falling. If tiny particles of dust become embedded in the liner, parts can get scratched during loading or unloading. If sewn fabric dunnage is exposed to rain, mold can grow and damage the rack bag itself. Fabric dunnage can be cleaned, of course, but an out-of-service bag is just costing you money.

Fabric dunnage gets dirty indoors, too. There’s always airborne dust in a kitting facility or on an assembly line. A roof can keep out the rain, but it won’t keep an assembler’s hands clean. If grease, grit, or grime gets on a part, you’ll need to clean the part’s surface and hope there aren’t any scratches. You may also need to clean the dunnage bag itself. Depending on the materials of construction, perhaps you can use a pressure washer. If you can’t, then add the cost of a cleaning challenge to the cost of your damaged parts.

Fabric Dunnage: Clean Designs, The Right Materials

Rack bag design that’s truly cost-effective isn’t just about CAD drawings and pocket sizes. You need a dunnage supplier who understands how rack bags are sewn, shipped, and used. Selecting the right fabric is an important part of this process. Brushed Tricot is a soft liner material that can be used with Class A surfaces, but this fabric is also a “dirt magnet”. So if you need rack bags for chrome parts or faux wood panels, thinks about what this means. Some scratches can be buffed out, but buffing isn’t free.

Hold-True can help you to get a clean, clear picture of your true dunnage costs. As an experienced supplier of sewn fabric products, we can meet your manufacturing requirements – including some you may not have considered. For example, when a heavy truck company needed to keep silicone greases off unpainted part surfaces, Hold-True used a different lubricant with its sewing equipment. Does your dunnage designer do things like that? To learn more how Hold-True can help you, contact us.

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