The Benefits of Using Overpacks

LINDEN, N.J. - Jan. 13, 2015 - PRLog -- The Benefits of Using Overpacks

Overpacking dangerous goods is a common technique that shippers use as a way to effectively combine one or more dangerous goods packages into a single unit. Although arranging a consignment of hazmat in an overpack is a small part of preparing the shipment, there are a number of dangerous goods regulations and practices that need to be adhered to.

The most common reason to utilize an overpack is to keep all of the packages of hazardous materials together, particularly if the shipment consists of a multitude of small boxes which could easily be lost during transit.  Overpacks are also utilized for hazardous material shipments to reduce the risk of pilferage.  When a shipment contains high end perfumes, iPads, or other high cost items, it is not uncommon for the value of a single pallet to exceed $100,000.  A well-constructed overpack can deter pilferage by making tampering of the overpacked unit easily visible to parties who take control of the shipment.

Tips for pilferage-proof overpacks:

Place the properly prepared dangerous goods packages within a Gaylord/pallet box.
Stretch wrap the overpack with custom printed wrap or colors that are not easily sourced.
Secure with tamper evident tape that displays a message when removed, or custom printed tape that cannot be replicated.
Utilize 4-way banding, custom printed if possible, or in a color that is not easily sourced.
Record accurate weight of the overpack and ask for intermediary handlers to check the weight of the overpack to ensure it matches correctly during all stages of the shipment.
Utilize wooden boxes or wooden crates as an overpack.

Overpack regulations

Overpacks of dangerous goods must adhere to all applicable regulations, whether it is CFR49, ICAO/IATA or IMDG code.  Some of these regulations can be difficult to locate and are often overlooked.

CFR49 contains a regulation which is often overlooked that can be found in 172.406 (e) (5)
Generally, only one of each different required label must be displayed on a package. However, duplicate labels must be displayed on at least two sides or two ends (other than the bottom) of—
(5) Each freight container or aircraft unit load device having a volume of 1.8 m3 (64 cubic feet) or more, but less than 18 m3 (640 cubic feet).

This regulation indicates that all of the required marks and labelling required by the hazardous materials regulations must be duplicated on two sides of the overpack.

Overpack regulation changes

Prior to January 1, 2015 dangerous goods shipments offered into transportation according to IATA (International Air Transport Association) Dangerous Goods Regulations (DGR) for packages that were prepared for cargo aircraft only had several limiting factors.

In the past under the IATA Dangerous Goods Regulations 55th edition section 5.0.1.5.3 The overpack must not contain packages bearing the “Cargo Aircraft Only” label except where:

(a) only one package is contained in the overpack; or
(b) two or more packages are contained in the overpack and the packages are assembled in such a way that clear visibility and easy access to them is possible; or
(c) the packages contain substances of:
•Class 3, Packing Group III, other than those with a subsidiary risk of Class 8;
•Class 6;
•Class 7;
•Class 9.

The section for overpack regulations in the IATA DGR 56th edition have been greatly simplified. Please read the following:

5.0.1.5 Overpacks
The shipper must ensure that where an overpack is used to enclose packages of dangerous goods, the requirements of 5.0.1.5.1 to 5.0.1.5.3 must be met:

5.0.1.5.1 The overpack must not contain packages enclosing different substances which might react dangerously with each other or packages of dangerous goods which require segregation according to Table 9.3.A.

5.0.1.5.2 Each package contained within an overpack must be properly packed, marked, labelled and be free of any indication of damage or leakage and in all respects be properly prepared as required in these Regulations.  Packages must be secured within the overpack.

5.0.1.5.3 The intended function of each package must not be impaired by the overpack.

With the updated regulations making overpacks of hazardous materials less obstructive, shippers should be encouraged to utilize consolidation methods for dangerous goods packages.

Other overpack benefits

Another benefit of overpacked hazmat packages is the lessened likelihood of the packaging being damaged during in transit. Packages placed on a pallet greatly reduce the chance of other packages, forklifts, pallet jacks, etc., coming into contact with packages causing damage.  An example of packaging that is highly susceptible to damage during transit are small steel drums, those of a capacity of less than 30 gallons.  Most common are 5 gallon steel drums.  These drums are notorious for easily incurring dents when shipped loose.

An easy solution to lessen this occurrence is for the UN specification drums to be packaged within a double or triple walled fiberboard box of a size just large enough to fit the drum, and to fill any void space with compressed kraft paper, foam, or other adequate fill material.

For multiple drums overpacked on a skid, it is recommended to use cardboard sheets to separate each drum from touching each other.  These drums should then be stretch wrapped with adequate pressure to firmly hold all of them together, without too much pressure (which could cause denting).  Additionally, the skid can then be banded for further resistance to movement of the hazardous cargo.

Reduced shipping costs

The final reason to consider using overpack methods is to reduce shipping costs.  Some carriers charge additional fees per piece for handling and to perform dangerous goods acceptance checks.  For example, if a dangerous goods shipment is being checked for conformity to the hazardous material regulations, and a shipment contains 400 packages, the amount of time, handling, and review would be extensive.  If that same shipment of 400 packages of dangerous goods is consolidated onto 10 pallets, the intrinsic value of time involved is greatly reduced, and that savings is passed along to the customer.

With all of the points covered, it is easy to see that overpacking hazardous materials is a judicious option to circumvent a multitude of problems - most of which can cause significant financial ramifications and time delayed cargo.

If you have any questions about your overpacks, dangerous goods packaging, crating or anything else transportation related, please contact DGM New York 601 W. Linden Avenue, Linden, NJ 07036 and we would be happy to assist you. In addition, please visit our website at www.dgm-usa-ny.com or email us at info@dgm-usa-ny.com.