A California commodities warehousing company came to Frisella Design requesting help with the design of a large shipping container, also known as a "gaylord". The company specializes in sugar warehousing. Their mission is to raise the standards of sugar warehousing from its existing condition, where mountains of sugar sacks create work hazards and attract vermin, to a much cleaner, safer and fully-automated environment.
As the gaylords are to be filled with sugar sacks on the ship docks, the design had to accommodate a very fast load and seal time of under 2 minutes. The other challenge was to keep the price of each gaylord to under $100.00, as thousands of these are to be manufactured for their first fully automated warehouse in Dubai. After discussing all of the manufacturing options with the client, the decision was to go with injection molding to keep the individual piece price low and source the mold tooling overseas to get the most competitive tooling price. The design was 3D modeled, then fabricated plastic full size prototypes were manufactured for testing the lid latching system and stacking strength. Based on the prototype testing, the 3D models were modified to increase the loading cycle, and the client signed off on the design.
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