In the automotive industry, it’s not just about propulsion and driving dynamics. Sometimes, it’s the subtle things that make a difference – especially when it comes to sustainability. Here’s the story of a cardboard box that goes on a world tour.
A significant challenge in global logistics is harmonising different packaging systems for intercontinental transport. In Europe, Euro pallets are standard, while in China and America, shipping containers of other sizes are often used. This variety of dimensions often hampers efficient transport and load capacity maximisation. The BMW Group recognised early on that packaging logistics holds enormous potential for efficiency and sustainability. In overseas shipments of automotive parts between Europe and international production sites from China to North America, the Bavarian car manufacturer is implementing innovative solutions that not only protect the environment but also save money.
Why are the BMW Group and its partners now stacking with PAL973?
At the centre of this development is the unassuming PAL973, a single-use paper box developed by BMW in collaboration with process partners: Project Oversea-Box. At first glance, it may look like an ordinary cardboard box, but behind this simple exterior lies a sophisticated system optimising overseas shipping.
Sabine Eller, Project Manager for Disposable Packaging at BMW Group Logistics in Garching near Munich, is confident: “When we talk about packaging logistics at the BMW Group, we can’t overlook our PAL973 in overseas shipping.” The enthusiasm in her voice is evident when she talks about the benefits of this innovation. The PAL973 is the result of a simple yet brilliant idea: Why not create a box that fits perfectly in a 40-foot shipping container? The result is a package that can be stacked three times on top and three times side by side. This seemingly simple arrangement maximises container space utilisation and provides optimal stability for the safe transport of sensitive components for automotive production.
“We have already saved on shipping containers in parts supply”
The PAL973 embodies the spirit of sustainability that runs through BMW’s entire logistics chain. Made from recycled corrugated cardboard, it is not only lightweight and durable but also fully recyclable. After use, it can easily be reintroduced into the material cycle – ideal for the circular economy in the automotive industry. “We’ve already saved on shipping containers when sending our parts,” says Sabine Eller happily. At a time when the cost of a 40-foot container has more than tripled since the end of 2023, every saved container is worth its weight in gold. The reasons for these price increases are varied, ranging from rerouting due to conflicts in the Red Sea to general disruptions in the global supply chain.
Ergonomics in the workplace: when the box serves people
With the introduction of the PAL973, BMW scores not only in sustainability statistics but also with the people who work with these packages daily. The PAL973 has a clever lift flap that allows employees to ergonomically access contents without the need to lift parts out of the box – a small but significant improvement for daily work.
