For one national supplier of outdoor pottery, weather damage was costing them time, money, and reputation.
They relied on corrugated paperboard sheets to stack and separate large ceramic pots during shipment to Home Depot distribution centers and retail locations.
But once those pallets hit the outdoor racks, things started falling apart—literally.
When you’re shipping heavy, delicate pottery across the country, the packaging between layers can make or break the delivery. Here’s how Solo Products helped one supplier turn weather-related failures into a long-term win.
The Problem: Water-Damaged Corrugated Sheets
The company stored stacked flower pots on pallet racks outdoors. But as rain and snow soaked the corrugated paperboard:
- The sheets weakened and collapsed
- Stacked pallets buckled or shifted
- Ceramic pots cracked or broke in transit
- Retailers received unsightly, unsafe displays
- Store teams spent time restacking damaged goods
It wasn’t just a logistics issue—it was hurting product presentation and increasing product loss.
The Solo Solution: Weatherproof Plastic Corrugated Sheets
Solo Products designed a solution that integrated with the supplier’s existing workflow, addressing the core issue of moisture-sensitive paperboard.
We provided:
- Rugged plastic corrugated sheets, custom die-cut to match their current stack dimensions
- Rain- and snow-resistant material that held up in outdoor storage
- Reusable, recyclable sheets that maintained their shape over time
- A system that their packers could use without retraining
The supplier immediately noticed stronger, safer pallet stacks, even in outdoor conditions, proving that small material changes can have a significant operational impact.
Results at a Glance
✅ No more stack collapse in wet weather
✅ Fewer damaged pots = less product loss
✅ Cleaner, more consistent retail displays
✅ No need to change the packout process
✅ Long-term durability with reusability built in
Why This Matters
If your business relies on fiber-based packaging in wet or outdoor conditions, you’re likely dealing with:
- Frequent replacement of soggy or warped sheets
- Product damage or collapse during shipment
- Inefficient use of labor at the point of sale
- Missed sustainability goals due to waste
Plastic corrugated offers a scalable, field-tested alternative.
Unlike single-use cardboard, these sheets can be reused for multiple shipping cycles, reducing waste and replacement costs—supporting both cost efficiency and sustainability goals.
Weatherproof Your Packaging Before Winter
From flower pots to food products to fragile stacked items, Solo’s plastic corrugated solutions help prevent avoidable damage and improve customer outcomes.
