How do you reduce DOA rates for defense electronics?
Discover proven strategies to minimize defense electronics failures through advanced packaging, testing protocols, and supply chain optimization techniques.
Discover proven strategies to minimize defense electronics failures through advanced packaging, testing protocols, and supply chain optimization techniques.
High-tech equipment is extremely vulnerable during transport, with shock, vibration and environmental factors causing costly DOA incidents. This article explains how engineered, custom packaging solutions significantly reduce damage risks, protect sensitive components, and lower total cost of ownership across the supply chain.
Dead-on-Arrival (DOA) rates reveal hidden costs and risks in your supply chain. This article explains how to accurately measure DOA in 2026, interpret the data, and identify root causes across packaging, handling, and transport. Learn how structured tracking helps reduce damage, protect margins, and improve customer satisfaction.
This article explains how a Total Cost of Ownership (TCO) analysis reveals that reusable packaging can be 30–50% more cost-effective than single-use packaging over time. By factoring in lifecycle costs such as handling, logistics, maintenance, and disposal, it shows why upfront price alone is a misleading decision metric.
A longer packaging lifespan directly lowers the total cost of ownership in defense logistics by reducing replacements, damage, and operational disruptions. This article explains why durable, reusable packaging delivers measurable cost savings over its full lifecycle. A must-read for decision-makers focused on reliability, compliance, and long-term value.
This article explains why damage costs are often underestimated in Total Cost of Ownership (TCO) calculations and how to properly account for them. By identifying direct, indirect, and hidden damage costs, it shows how smarter packaging decisions can significantly reduce long-term operational and financial risk.
Modular design reduces Total Cost of Ownership in defense supply chains by replacing bespoke packaging with standardized, reconfigurable systems. This approach lowers inventory complexity, improves asset utilization, and increases logistical flexibility across missions and platforms. It shifts packaging from a cost center to a strategic enabler of readiness and efficiency.
This article explains why Total Cost of Ownership (TCO) in industrial packaging goes far beyond purchase price, covering hidden costs such as damage, handling, storage, and compliance. It provides realistic TCO benchmarks per sector and shows how strategic packaging decisions can significantly reduce long-term logistics costs while improving reliability and sustainability.
Reverse logistics transforms transport cases from single-use costs into circular assets. By enabling reuse, refurbishment, and higher utilization, companies can significantly reduce Total Cost of Ownership while improving sustainability and supply chain control.
Circular packaging solutions reduce Total Cost of Ownership by spreading costs over multiple reuse cycles, lowering waste, logistics, and compliance expenses. In 2026, companies that treat packaging as a long-term asset gain both financial efficiency and measurable sustainability impact.
Dead-on-Arrival (DOA) is a major hidden cost in international shipping. This article explains the main causes of DOA, from transport stresses to packaging failures, and shows how smart packaging strategies can significantly reduce damage, returns, and risk across global supply chains.
Sensitive measuring equipment is highly vulnerable to transport vibrations, often leading to hidden damage and high DOA rates. This article explains how effective vibration-damping packaging absorbs shocks, preserves accuracy, and significantly reduces transport-related failures.
Maintenance costs play a decisive role in the Total Cost of Ownership of industrial cases, often exceeding the initial purchase price. This article explains which hidden and indirect maintenance costs impact TCO, and how preventive maintenance strategies can significantly reduce long-term packaging costs while minimizing downtime and risk.
Many procurement teams focus on upfront packaging costs, while overlooking critical Total Cost of Ownership factors. This article explains how hidden costs such as damage risk, handling time, storage inefficiency, and replacement frequency significantly impact long-term spend. A must-read for procurement professionals aiming to make smarter, lifecycle-driven packaging decisions.
This article explains why total cost of ownership matters more than purchase price when choosing between custom flightcases and standard solutions. By comparing lifecycle costs such as damage, efficiency, lifespan, and logistics, it shows when custom cases deliver measurable long-term value.
This article explains how to calculate the Total Cost of Ownership (TCO) for high-tech equipment packaging by looking beyond purchase price alone. It shows how lifecycle costs such as damage prevention, reuse, logistics efficiency, and end-of-life handling determine the true financial impact of packaging decisions.
Total Cost of Ownership (TCO) reveals the true cost of packaging by looking beyond purchase price to the full lifecycle impact. By factoring in handling, transport, damage prevention, and sustainability, companies make smarter packaging decisions that reduce risk and lower long-term costs.
Reusable packaging lowers Total Cost of Ownership in the medical sector by reducing hidden costs such as waste, damage, compliance risk, and recurring procurement. By focusing on lifecycle costs instead of purchase price, medical companies achieve higher efficiency, lower risk, and measurable ROI within 12 – 24 months.
Choosing the right foam interior is critical to reducing DOA risk for sensitive sensors. This article explains how anti-static and conductive foams, correct density selection, and custom-fit designs protect against shock, vibration, and electrostatic discharge during transport.
Custom packaging plays a critical role in reducing Dead-On-Arrival (DOA) rates for automotive components by protecting parts against shock, vibration, moisture, and contamination. By tailoring materials and internal designs to each component, manufacturers can prevent damage, avoid production delays, and significantly lower total supply chain costs.
This article explains how targeted transport tests such as vibration, shock, temperature, and humidity testing help predict and reduce DOA risk. By identifying the most critical stress factors early, companies can design packaging that prevents damage, lowers costs, and protects high value products throughout the supply chain.
This article explains how to correctly report Dead on Arrival (DOA) damage for insurance claims, including strict timelines, required documentation, and common pitfalls. It shows why proper evidence and packaging records are critical to claim approval and how better packaging can prevent costly DOA incidents altogether.
A high DOA rate silently drives up costs far beyond product replacement, impacting logistics, operations, and customer trust. This article explains how hidden inefficiencies compound annually and why structurally engineered packaging is key to reducing risk and total cost.
Transporting high-value equipment involves strict insurance requirements that go far beyond standard liability coverage. This article explains which transport insurances apply, how international regulations impact coverage, and why packaging quality plays a critical role in risk mitigation and claim acceptance.
Field services stand or fall on good preparation. In this white paper, you can read how well-designed packaging supports maintenance and service of machines and installations, prevents disruptions, and reduces failure costs. Practical, recognizable, and written from the daily reality of technical services.
This article explains the key differences between standard transport crates and custom packaging solutions, focusing on risk reduction, logistics efficiency, and total cost of ownership. It shows why custom solutions are often the more cost-effective and sustainable choice for transporting high-value or sensitive equipment.
Optimizing case design for stackable storage is key to reducing space usage while maintaining protection and stability. By combining smart material choices, balanced weight distribution, and modular design, stackable cases improve logistics efficiency and lower total storage and handling costs.
This article explains how custom-engineered foam interiors are designed to protect high-value equipment against shock, vibration, and transport risks. It outlines the material selection, design, and testing process, showing how optimized foam solutions reduce damage, prevent DOA, and lower total cost of ownership.
This article explains which hinge mechanisms perform best in heavy-duty applications, focusing on load capacity, material choice, and durability. It highlights how hinge design and testing influence long-term reliability in demanding industrial environments.
This white paper shows how smart, digitally connected packaging solutions help reduce risks, maintain control over global flows, and lower CO₂ impact. The result: a supply chain that is not only more robust and sustainable, but above all more manageable in a world where mistakes are becoming increasingly costly.
The ADR rules for lithium battery transport are becoming stricter, with new requirements for classification, UN-certified packaging and documentation. This article clearly explains what is changing for UN3480/3481 and UN3090/3091, including packaging instructions and risks of non-compliance. Essential reading for anyone who wants to transport lithium batteries safely and in accordance with legislation.
Lithium batteries may only be exported if they comply with strict safety and transport regulations. This includes checking their physical condition, UN 38.3 certification, correct documentation and safe, UN-certified packaging. Without these checks, regular transport is not permitted.
The safe storage of lithium batteries requires stable temperatures around 0–25 °C to prevent risks such as degradation, swelling or even thermal runaway. The article explains why temperature control, monitoring and correct storage conditions are crucial for the safety and service life of every lithium battery.
Plastic welding offers a stronger, more durable and more reliable connection than traditional adhesive techniques. This technique makes customised packaging more robust, consistent and resistant to demanding industrial conditions. Faes is taking a new step forward in quality and production stability with this technique.
Flammable liquids pose significant risks during storage and transport. This article explains the legal requirements (ADR, IMDG, IATA) and practical hazards and shows how the correct UN-certified packaging prevents incidents.
TCO optimisation shifts the focus from purchase price to the full lifecycle of industrial packaging, revealing where hidden costs drive inefficiency. By choosing durable, reusable solutions and improving handling, logistics and damage prevention, companies can significantly reduce total packaging costs in 2025 and beyond.
Most companies underestimate the real cost of their logistics packaging by focusing only on the purchase price. This article explains how hidden expenses like damage, handling, transport and sustainability compliance shape the true Total Cost of Ownership in 2025, helping you make smarter and more future-proof decisions.
Strict international standards apply to the safe transport of lithium-ion batteries due to the high risk of fire and explosion. This article explains which regulations apply, which UN-certified packaging is required, and how companies can limit risks with the right materials and procedures.
Total Cost of Ownership (TCO) allows companies to look beyond the purchase price and reveals all logistical costs over the entire lifespan. It uncovers hidden costs such as damage, maintenance and inefficiency, enabling you to make informed choices. For example, a more expensive packaging solution often turns out to be the cheapest in the long term.
Failure to comply with REACH leads to substantial fines, supply chain disruptions and lasting damage to reputation. The article emphasises how crucial correct documentation, chain responsibility and continuous monitoring are to prevent risks and ensure business continuity.
REACH is the European framework that regulates the use of chemical substances across the entire supply chain, requiring companies to demonstrate safety and transparency. This article explains how REACH affects materials, packaging design, and compliance obligations for industrial manufacturers, and how Faes supports companies in becoming fully REACH-proof.
TCO optimization for industrial packaging goes beyond just the purchase price. It encompasses all costs during the entire lifecycle – from acquisition to waste disposal. Companies that apply this holistic approach discover that investments in higher quality packaging solutions often result in cost savings and contribute to sustainability goals. Discover which cost components are included and how circular packaging can significantly reduce the TCO.
Dead-on-arrival prevention is the cornerstone of reliable industrial logistics. By mapping every risk in the supply chain and designing custom protective solutions, Faes ensures that high-value equipment arrives exactly as intended: fully operational and damage-free.
Discover how to calculate the true total cost of industrial packaging in 2025. Learn how a Total Cost of Ownership approach that includes design, logistics, maintenance and sustainability helps you save costs, reduce waste and strengthen your supply chain.
Understanding the difference between acquisition costs and Total Cost of Ownership (TCO) is essential for smart logistics investments. Faes explains how sustainable, reusable packaging may cost more upfront but delivers long-term savings through reduced maintenance, waste, and lifecycle expenses.
Faes explains how DOA preventive packaging minimizes transport damage, reduces costs, and boosts reliability in high-tech logistics. By using tailored materials and shock-absorbing designs, it safeguards sensitive equipment and ensures every delivery arrives in perfect condition.
Discover how to calculate the true Total Cost of Ownership (TCO) for your logistics packaging. This Faes guide explains how hidden costs such as transport inefficiencies and product damage affect profitability and shows why a lifecycle approach results in smarter, more sustainable packaging decisions.
Faes highlights the difference between standard packaging and DOA preventive packaging. DOA solutions are custom engineered to ensure products arrive functional and undamaged, reducing failure costs and increasing reliability throughout the logistics chain.
Many companies optimize their production, but overlook waste in their packaging logistics. When examining the return process through the lens of the TIMWOODS method, it becomes apparent that the real gains are often found in movements, waiting times, and routines that do not add value. Doing less can yield surprising results—in terms of time, costs, and sustainability.
Learn how vibration testing helps prevent transport damage and optimise packaging. Faes explains which test methods most realistically simulate the transport of equipment and how international standards such as ASTM D4169 and ISO 13355 increase reliability.
Professional transport cases must meet strict standards such as ISTA, ASTM, ISO and MIL-STD-810 to protect their contents from shocks during transport. These drop tests assess structural integrity, water resistance and protection of contents, and are crucial in sectors such as defence, high-tech and medical equipment.
Discover how smart packaging management drives sustainability by enabling reuse, repair, and data-driven optimization. Faes shows how circular systems reduce CO₂ emissions, cut waste, and ensure compliance with upcoming EU regulations.
Packaging management is a strategic approach that optimizes the entire packaging lifecycle, from design and materials to logistics and sustainability. It uses data-driven insights and circular practices to reduce costs, improve efficiency, and strengthen brand consistency across the supply chain.
Strategic packaging management transforms packaging from a cost center into a driver of supply chain efficiency. By optimizing design, materials, and lifecycle, businesses reduce costs, minimize damage, and enhance sustainability across the entire logistics chain.
Shockproof packaging protects sensitive equipment from shocks, vibrations, and impacts during transport, reducing damage costs by up to 80%. By combining durable materials with smart design, it ensures product integrity, compliance, and sustainability throughout the supply chain.
Wooden packaging outperforms plastic when strength, durability, and sustainability are key. It offers superior shock absorption, temperature resistance, and long-term cost efficiency, making it ideal for heavy loads, sensitive equipment, and circular logistics strategies.
Learn how to make packaging suitable for air and sea freight with expert insights from Faes. Discover key material choices, weight and moisture management, and compliance with IATA and IMO standards to ensure safe, efficient, and sustainable transport.
Learn how to choose the ideal interior for a custom case to protect your equipment. This Faes guide explains the differences between PE, PU, and EVA foams, offers tips for precise measuring, ergonomic design, and production methods like waterjet cutting to ensure perfect fit and durability.
Adapting packaging to different product loads requires a smart balance between protection, cost, and sustainability. By analyzing product characteristics, transport conditions, and load distribution, and validating designs through testing, you ensure safe, efficient, and eco-friendly packaging solutions.
The new FuelEU Maritime regulation is putting pressure on the maritime sector to reduce CO₂ emissions. This whitepaper explains how industrial packaging can serve as a direct lever to cut Scope 3 emissions while saving costs across the logistics chain. Discover concrete strategies and real-world cases that show how efficient packaging contributes to a more sustainable and future-proof supply chain.
Preventing short circuits in lithium-ion transport demands rigorous insulation of terminals, use of non conductive separators, and shock-resistant packaging to stop internal or external contact. Mistakes here can lead to thermal runaway, fires, or explosions.
Correct insulation materials are a legal necessity for battery packaging to prevent short circuits, thermal runaway, and chemical leaks under ADR, IATA, and UN rules. Approved options include non conductive materials like vermiculite, fiberglass, ceramic fibers, and special foams that offer flame resistance, electrical insulation, and shock absorption.
Accurate documentation of lithium battery shipments is mandatory under ADR, IATA, and IMDG regulations, including correct UN numbers, packaging certificates, safety data sheets, and emergency contacts. Common errors such as missing statements or incorrect details can lead to fines, shipment delays, or refusals.
Incorrectly shipping lithium batteries can result in severe fines, legal action, and reputational damage. Regulations like ADR, IATA, and IMO require strict compliance in classification, packaging, labeling, and documentation. Noncompliance can lead to penalties up to €40,000 and potential criminal prosecution.
The article explains how selecting the right gasket material, such as silicone, EPDM, neoprene or natural rubber, is essential for achieving long-term water tightness in industrial enclosures. It outlines the strengths and limitations of each material, their impact on IP ratings and the environmental factors that influence durability.
Are you only looking at the purchase price of transport cases? Then you’re missing the big picture. Total cost of ownership (TCO) provides a complete picture of all costs: purchase, use, maintenance and disposal. This article shows how to fairly compare single-use and reusable transport solutions, which hidden costs are often overlooked, and when investing in premium quality is financially smart. Discover how the correct TCO calculation can save you thousands of pounds.
Faes explains how to compute foam compression to secure your product snugly yet safely by using the ratio of original to compressed thickness. The guide shows how foam type, density, product weight, and environmental conditions all influence the ideal compression for safe transport.
Faes explores which aluminum alloys deliver the best strength per unit weight, concluding that 7000-series alloys (notably 7075-T6 and 7068) lead the pack. The article also shows how 2000- and 6000-series alloys balance other traits like fatigue resistance and corrosion performance.
Learn how rotationally molded and injection molded cases differ in production, durability, precision, and cost. Faes explains how these factors determine the best solution for your application and budget.
Discover how to determine the optimal wall thickness for your case by considering material, load, and usage conditions. A wall that’s too thick means unnecessary weight and costs, while a wall that’s too thin provides insufficient protection. Learn the calculations, test methods, and factors that are crucial for finding the perfect balance between protection and practical use.
Explore how to choose coatings that resist chemical aggression in harsh environments. Faes discusses the comparative strengths of fluoropolymers, epoxies, and other barrier systems, and offers guidance for matching coatings to specific chemicals and use-cases.
Learn how to calculate internal volume accurately to maximize packaging efficiency. Faes explains measurement methods, formulas, and smart design tips to optimize space, reduce costs, and enhance protection.
Custom packaging streamlines logistics by reducing product damage, saving space, and improving handling efficiency. Faes shows how tailored solutions boost sustainability, cut costs, and optimize the entire supply chain.
Foam interiors provide reliable protection for sensitive equipment by absorbing shocks, vibrations and impacts during transport. With tailored density and design, they keep fragile parts secure while extending the lifespan of both packaging and product. Choosing the right foam ensures durability, re-usability and cost savings over time.
Efficient packaging relies on smart storage and stackability. With the right materials and design, you save space, cut costs, and protect products throughout the supply chain.
Industrial custom packaging ensures maximum protection and logistics efficiency by perfectly fitting the product and its conditions of use. It reduces damage and transport costs while meeting the strictest standards in sectors such as high-tech, medical, and defense. At the same time, it supports sustainability through reuse and circular design.
Custom flight cases typically take 2 to 8 weeks to produce, depending on design complexity, materials, and certifications. By planning early and providing clear specifications, you can streamline the design process and reduce lead times.
A temperature test shows whether packaging can withstand extreme cold and heat, ranging from −40 °C to +80 °C or even further. Realistic climate simulations are used to check whether materials, closures and seals remain reliable, so that products can be transported and stored safely and in accordance with international standards.
A vibration test shows whether an industrial package adequately protects products during transport. Together with our renowned partners, we simulate realistic conditions and translate these results into concrete improvements for optimal safety.
An IP test determines how well a package is protected against dust and water according to the international IEC 60529 standard. Through testing by our reputable partners, the IP code provides assurance about the reliability and safety of your packaging. We guide you from analysis to certification so that your products are always optimally protected.
Learn how a drop test for cases and crates works: from drop height and test standards to design, implementation and reporting. Learn how Faes works with test partners to ensure the protection, quality and reliability of packaging against damage during transport.
Discover why logistics failures are often the hidden culprits behind DOAs and how simple adjustments to packaging and processes can immediately yield significant gains. Read how you can transform logistics from a blind spot into a strategic asset for your supply chain.
Discover how you can significantly reduce the risk of defective deliveries (DOAs) right from the design phase by incorporating smart packaging, material and installation factors. Learn how Design for Distribution prevents technical choices from causing headaches, costs and quality losses later in the chain.
Field Service Engineers play a crucial role in reducing DOAs. With the right training, tools, and installation scripts, you can prevent errors, save time, and increase the reliability of your service.
A defective part upon arrival costs much more than you might think. Once you factor in service hours, urgent transport and stock costs, the damage can amount to between 135 and 219 per cent of the material value. Understanding the causes is crucial to protecting margins and securing growth.
Discover how logistics errors, component quality and service quality together cause the hidden costs of DOAs. This article shows how root cause analysis and smart improvements can make your supply chain more reliable and cost-efficient.
IATA regulations determine whether your air freight will travel smoothly around the world. Discover how the right packaging prevents shipments from being rejected and how you can minimise costs, delays and risks.
Discover how reducing packaging variants drastically improves the service chain: lower costs, fewer DOAs and higher customer satisfaction. This article shows how smart choices in packaging deliver immediate results.
The EU Battery Regulation imposes strict requirements on the transport and packaging of lithium batteries from 2027 onwards. This article provides insight into new rules concerning QR codes, Battery Passports, return flows and recycling targets.
DOAs may seem like complaints, but they are primarily signals that help improve your supply chain. By analysing causes and optimising processes, you reduce costs, increase reliability and strengthen customer relationships. Faes shows how smart DOA management leads to competitive advantage and sustainability.
ADR regulates the safe transport of dangerous goods and sets strict requirements for industrial packaging. From UN markings to labelling and compatibility, compliance prevents fines and guarantees safety and continuity in the supply chain. Faes helps companies make their packaging fully ADR compliant.
Urgent shipments seem like a quick solution for DOAs, but they can drive costs up to eight times higher than regular transport. This article shows how prevention, detection, and smart inventory strategies not only reduce costs but also structurally increase reliability and customer satisfaction.
Vulnerable equipment on construction sites is at risk from moisture, dust, impact and incorrect handling. Customised packaging ensures maximum protection and a longer service life. We combine technical expertise and recognised standards to keep field equipment safe for use.
The new EU PPWR regulation will impose strict requirements on industrial packaging from 2026 onwards. Companies must focus on reuse, recyclability and digital traceability in order to remain compliant. This article explains what is changing and how your organisation can prepare.
Dead on Arrival products incur high costs due to transport, stock and repair work. This article explains who is responsible for these costs and how better packaging and chain collaboration can structurally reduce the number of DOAs.
Dead-on-arrival parts may seem like a minor issue, but their impact is significant. On average, companies lose more than 4% of their spare parts revenue due to defective deliveries. Discover the hidden costs and how you can limit them in this article.
DOAs have a direct impact on service levels and increase costs due to additional demand, urgent deliveries and higher stock levels. This article shows how fill and ready rates come under pressure and offers strategies to limit damage and gain a competitive advantage.
Packaging as a Service transforms packaging from a cost item into a strategic tool for cost control, circularity, and compliance. The white paper demonstrates how this model assists companies in operating more sustainably and efficiently within the requirements of the EU Packaging Regulation.
Increasing stock seems like a quick fix for DOA, but often incurs high costs without addressing the real cause. This can only be useful in cases of exceptionally high defect rates, whereas structural improvements in packaging and logistics are almost always more effective.
Dead-on-arrival products cause more damage than just return costs and replacements. They disrupt production processes, strain customer relationships and increase the ecological footprint. Through better packaging strategies and chain-wide collaboration, Faes helps companies to prevent these hidden costs on a structural basis.