Fiberglass components, automotive trim, coated metal parts, medical devices – each of these products places different demands on their transport packaging. Scratches are caused by unsecured parts, incorrect positioning due to sliding loads, moisture damage due to inadequate climate sealing. Conventional wooden crates or disposable packaging solve the problem temporarily – at the expense of procurement time, disposal logistics and above all: return transport capacity.
Foldable large load carriers with ThorPak Solution/Steel inner systems create a reproducible, scalable answer: individually adapted protection concepts in full loads, space-saving return in empties.
Typical challenges with sensitive goods
Sensitive components often fail during transportation – not due to a lack of care, but because of systemic gaps in the packaging solution. The most common causes of damage in B2B transportation practice:
Protection concepts: padding, fixation, climate protection
An effective protection concept for sensitive goods combines three active principles: Cushioning (shock absorption and surface protection), fixation (secure positioning) and climate protection (humidity and temperature control). The ThorPak Solution/Steel system addresses all three levels with modular insert systems:
Foam compartments
Foam glued to Aircell panels. All parts removable. HKP base for precise moldings. Ideal for precision parts and electronics.
Textile compartments
Folds with the container ring – remains clean and ready for use even when folded. Scratch-resistant design for coated surfaces.
Numbered compartments
Storage compartments with foldable curtain, can be moved individually. Numbering enables component tracking without a barcode scanner.
Fixation
Toothed strips, loading flap with Velcro/flange, collision protection. Locator system locks pallet with container ring positively.
Aircell covers
Aircell lid with hinge – temperature-stable from -20 °C to +50 °C, tested to ISO 8611 with 2-fold safety.
Tray and steel systems
Deep-drawn intermediate layers for precise component support. Special aluminum frame with foam compartments for suspended components (Top-Front-Loader System 1208 with steel struts).
All storage compartments and compartments are individually adapted to the packages – compartment materials can be selected from textile, foam, plastic and steel. The return ring allows the foldable ring and the compartment to be folded together for return transportation (sandwich system) without dismantling the inner system. Details of the container design: ThorPak Solution/Steel product page.
80 % volume reduction during return transport
The economic superiority of foldable large load carriers is most evident in the return transportation of empties. A non-foldable container occupies exactly the same loading space during return transport as it does when loaded – a structural inefficiency that is repeated with every round trip.
Foldable ThorPak systems reduce the transport height to 220-258 mm when folded (depending on type). This enables a stacking factor of 1+10 – eleven empty containers require the same space as one full one. For the ThorPak Medium T 1200×800, this means that 102 full containers fit on a standard truck – empty, folded, there are 374 of them.
| Typ | Höhe Vollgut | Höhe gefaltet | LKW Vollgut | LKW Leergut | Faktor |
|---|---|---|---|---|---|
| MT 1200x800xH900 | 900 mm | 254 mm | 102 | 374 | 3,7 x |
| MT 1350x800xH1000 | 1000 mm | 245 mm | 90 | 330 | 3,7 x |
| MT 1600x800xH900 | 900 mm | 236 mm | 72 | 264 | 3,7 x |
| MT 1800x1200xH1000 | 1000 mm | 245 mm | 42 | 154 | 3,7 x |
| MT 2400x1200xH1000 | 1000 mm | 245 mm | 33 | 121 | 3,7 x |
Source: ThorPak size chart DE, wi-sales GmbH, 01-2024. Specifications are based on ISO 8611 tests at 20 °C and uniformly distributed loads.
With the ThorPak Solution with full container ring and textile compartments, the ring folds together with the textile – 4 boxes folded into the space of a standing box. The sandwich system holds the pallet, ring and compartments as a single unit, which is moved by pallet truck. No disassembly of the inner system required.
ThorPak solutions for sensitive products
wi-sales offers several product lines for the transportation of sensitive goods. The choice depends on component size, protection requirements, throughput volume and cycle structure:
ThorPak Solution / Steel
Foldable GLT/steel frame with textile, foam, compartment, tray and steel systems. Top loader, front loader, top front loader and container with chassis (4 folding side walls). Individually adapted to packages. Widths 800-2400 mm. All storage compartments customized.
ThorPak Medium T
Standard GLT with M-fold, container ring 10 mm PP 3000 g/m². Stacking factor 1+4 (full containers), 1+10 (empties). Payload 250-300 kg. Tested -20 °C to +50 °C in accordance with ISO 8611. Available as front loader for door panels and as variant 1612 with textile compartments.
ThorPak Quattro
No folding sequence, can be folded as required. Textile, foam and plastic compartments, several compartment levels possible. Printable, stackable, steel-reinforced. Up to 4000×1200 mm external dimensions.
All systems can be combined with Aircell air chamber panels as intermediate and cover layers – a third of the weight of a solid panel with the same flexural rigidity. ThorPak carrier systems (800×800 to 1900×800 mm) are available for stacked transport of KLT, EPP/EPE foam containers and stacking boxes.
ROI calculation: reusable vs. disposable
The crucial question for purchasers and logistics managers is not: How much does the container cost? – but: What is the cost of transportation per component over the entire service life? Reusable GLTs are amortized through usage cycles and return transport savings.
The following comparison shows exemplary cost structures. Individual calculations – depending on the number of cycles, distance, component value and damage rate – are available from wi-sales on request.
| Kostenposition | Einweg (Holzkiste/Sonderverpackung) | Mehrweg ThorPak |
|---|---|---|
| Verpackungskosten je Einsatz | 100-300 € (je nach Größe) | Abschreibung über 10+ Jahre Nutzungsdauer |
| Rücktransport (Leergebinde) | Vollpreis - kein Platzgewinn | Bis zu 73% weniger LKW-Fahrten (Stapelfaktor 1+10) |
| Beschaffungsaufwand | Jedes Mal neu beschaffen und ordern | Einmalig - Kreislauf stabil |
| Entsorgungskosten | Vorhanden (Holz, Folie, Sondermüll) | Entfällt |
| Schadensquote | Abhängig von Einzelfertigung und Handling | Reproduzierbar niedrig durch bauteilspezifisches Gefach-System |
| Amortisation | — | Typisch nach 15-30 Umläufen |
Additional leverage: Every avoided transport damage not only saves the value of the goods, but also complaint processing, new production and delivery delays. In the case of high-value components (automotive, medical technology, electronics), damage avoidance often exceeds the packaging investment in the first year of use.
Frequently asked questions
What is a foldable large load carrier (GLT)?
A foldable large load carrier is a reusable transport container with a base area of at least 800×600 mm, which can be reduced to approx. 20-25% of its full height when empty by folding the container ring. ThorPak systems from wi-sales are made of high-quality PP plastic (10 mm, 3000 g/m²), optionally steel-reinforced and available in sizes from 800×600 to 2400×1200 mm.
How does ThorPak protect sensitive components from transport damage?
ThorPak Solution/Steel systems combine foam on Aircell panels for shock absorption, textile compartments for scratch-free surfaces, numbered storage compartments for secure positioning and loading flaps with Velcro/fleece and collision protection. All compartment components are adapted to the specific component. The temperature range extends from -20 °C to +50 °C (ISO 8611 tested).
How much volume is saved when returning foldable GLTs?
A ThorPak Medium T 1200×800 H900 reduces its transport height from 900 mm to 254 mm. Thanks to the stacking factor of 1+10, 374 folded instead of 102 full containers fit on a standard truck. The ThorPak Solution system also allows rings and compartments to be folded together in a sandwich system – 4 boxes folded in the space of a standing box.
What protection concepts does wi-sales offer for sensitive goods?
wi-sales offers five system variants: Textile compartments (scratch-proof, foldable with ring), foam compartments on Aircell panels, compartment systems with numbered sliding compartments, tray systems with deep-drawn intermediate layers and steel systems with aluminum racks for hanging components in the top front loader. Combinations and multiple compartment levels are possible. All systems can be customized.
When does a reusable GLT start to pay off compared to disposable packaging?
In typical B2B logistics cycles, experience has shown that a ThorPak system pays for itself after 15-30 cycles, depending on acquisition costs, savings in one-way costs and return transport savings due to foldability. For high-quality components with a reduced damage rate, the return on investment can occur earlier. wi-sales can provide individual ROI calculations on request.
What sizes and variants are available for the ThorPak Solution?
The ThorPak Solution is available in customer-specific sizes from 800×600 mm to 2400×1200 mm. Top loader, front loader, top front loader and container with chassis (4 hinged side walls) are available as loader versions. All systems can be supplied with an individually printed container ring (10/3000 PP).
Contact us now by phone, e-mail or form and make an appointment with the specialist for reusable transport and storage containers. Get started and get one step closer to your goal.
Keyword: “Sensitive goods”
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