Company: A leading foam products exporter based in Ho Chi Minh City, Vietnam.
Annual Export Volume: Approximately 1,200 containers of polyurethane foam sheets, rolls, and finished sleep products.
Markets Served: Southeast Asia, Middle East, North America.
Key Challenge: High freight costs due to bulky foam shipments and inefficient packaging processes.
Excessive Shipment Volume
Conventional packaging of foam sheets and rolls occupied up to 70% of container space, leading to frequent underutilization and high per-unit freight charges.
Rising Logistics Expenses
In 2024, the client's average shipping cost per cubic meter rose by 15% due to global fuel surcharges and container shortages.
Manual Handling & Labor
Manual rolling and strapping processes were time-consuming, labor-intensive, and prone to inconsistent compression ratios.
Automatic Compression: High-strength rollers achieve up to 8:1 compression ratio for foam blocks and rolls.
Integrated Roll-Packing: Built-in stretch-wrapping system applies 3 layers of film, ensuring stable, dust-free bundles.
PLC Control & Touchscreen HMI: Simple recipe-based controls to adjust compression pressure, roll diameter, and film tension.
Continuous Production Line: Capable of handling up to 20 foam rolls per hour, with minimal manual intervention.
Site Assessment & Layout Design
NAIGU engineers conducted a 2-day on-site survey to plan machine placement, material flow, and power requirements.
Installation & Commissioning
The NG-13RL was installed in 5 days, followed by 3 days of operator training and trial runs.
Integration with Workflow
Foam sheets loaded into infeed conveyor.
Automatic compression and roll formation.
Wrapped bundles discharged onto pallets for forklift pickup.
| Metric | Before NG-13RL | After NG-13RL | Improvement |
|---|---|---|---|
| Container Utilization Rate | 70% | 92% | +22 pp |
| Average Logistics Cost (USD/m³) | $65 | $39 | –40% |
| Labor Hours per 100 Rolls | 15 | 4 | –73% |
| Throughput (rolls/hour) | 8 | 20 | +150% |
40% Logistics Cost Reduction
By compressing foam to a smaller volume and maximizing container space, the exporter lowered freight costs from $65 per cubic meter to $39 per cubic meter.
Higher Throughput & Lower Labor
Automation reduced manual labor by 73% and increased line capacity by 150%, enabling faster order fulfillment.
Improved Customer Satisfaction
Secure, uniform packaging minimized product damage and dust contamination, strengthening client confidence in delivery quality.
Learn More
Contact NAIGU today to discover how the NG-13RL can transform your foam packaging and logistics strategy:
