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A press shop runs three shifts, and by the second shift the original cardboard sleeves on stamped brackets are gone or illegible. Line crews start guessing which bin holds which part number, and scrap climbs. The fix most European plants land on is a returnable dunnage set built from polypropylene twinwall board, and the color of that board is not decoration: it is the label.
Why orange carries the message. Orange skin sheets stand out against grey steel racks, blue totes and white walls, so a missing or misplaced container is noticed in seconds rather than at the end-of-day count. Plants that sort mixed families of brackets, clips and trim use one color per part family, and orange is usually reserved for the family that cannot afford a mix-up: safety-relevant or high-value components.
Structure that survives the loop. The fluted core gives the sheet its stiffness in two directions, so a folded bin wall keeps its shape fully loaded, while the flat skin takes printed labels and barcode stickers without delaminating. Sheets are cut to size, creased on a routing table and closed with ultrasonic welds or hot-melt tape, so there are no rivets or staples to snag parts or tear gloves.
Spec list:
OR 1210 sheet: 1200 x 1000 mm, 4 mm twinwall, 780 g/m2, flat crush 1.2 kN.
OR 0604 sheet: 600 x 400 mm, 3 mm twinwall, 560 g/m2, for divider sets.
OR 1212 corner board: 1200 x 120 mm, 5 mm twinwall, edge protector duty.
Folded bin stack: five high empty, two high loaded, 1.9 kg tare per bin.
Nesting ratio: 78% empty bin-to-bin, no tools needed to collapse.
From drawing to dunnage. Send us the bin or rack drawing with payload and part family, and we come back with a cutting and creasing layout, a sheet gauge recommendation and a welded or taped closure plan. Samples are produced from the same orange stock as the production run, so what you validate is what you receive. Standard sheet sizes ship in 10 to 15 days; custom welded sets follow sample approval.
If your plant is ready to move one part family off cardboard this quarter, send the drawing to TOYOE and we will quote the orange dunnage set within two working days.
