We collaborated with a long-standing Export Packing customer to design and produce a bespoke aluminium 3D Barrier Bag solution for a uniquely shaped Electrical Tug, ensuring:
- Tailored 3D fit for complex machinery
- Maximum protection from moisture and corrosion
- Hermetic sealing with BSI-compliant desiccant levels
- Optional smart features for Customs inspection and humidity monitoring
Custom 3D Barrier Bags: Aluminium Barrier Foil Packaging for Electrical Tugs
Our customer, a specialist Export Packer, required a moisture-resistant packaging solution for an electrical Tug—a large piece of machinery with an irregular shape, similar to a small steam train. The machinery was being shipped overseas and needed robust protection against corrosion and humidity.
Customer's Challenge
The client needed a packaging solution that could:
- Fit a complex shape precisely
- Prevent moisture ingress and corrosion during global transit
- Be securely sealed with desiccant
- Offer optional visibility for Customs without breaking the seal
- Monitor internal humidity without reopening the bag
Our Solution
Working in close consultation with the customer, we designed a custom two-part 3D aluminium barrier foil bag, internally nicknamed the “Train Bag.” The packaging comprised:
- A fitted base tray for the Tug to sit in securely
- A contoured upper cover to enclose the machinery
- Hermetic heat sealing of both parts with pre-calculated desiccant inside
- Optional features such as a clear Customs inspection window and screw-in humidity indicators
Custom drawings and ongoing design consultation throughout the project
Outcome
The final solution delivered complete peace of mind for the customer:
- Moisture and corrosion protection during international transit
- No need to open bags for inspection, thanks to optional features
- Fast turnaround and no minimum order quantity
- Full compliance with international packaging standards
We thrive on solving complex packaging challenges for industrial and export customers. Our team is here to create bespoke barrier foil packaging that safeguards your goods from production to delivery, no matter the shape, size, or shipping destination.
Do you have a need you would like to discuss?
Talk to our team of experts who will be happy to work with you to develop a solution.