Best Practices for Protecting 4x8 Substrates During Customer Pickup

[czar2178]

I’m curious to learn what methods you all use to protect 4x8 substrates like Foam Core, Coroplast, or Acrylic until your customers pick them up. Currently, I use a significant amount of shrink wrap after completing a job. While this usually works well, I’ve been doing a lot of work for wedding planners recently, and they tend to be very particular about the presentation and condition of materials.

I also use cardboard pads to sandwich the substrates for added protection, but with rising costs, this approach is becoming less feasible.

Does anyone know where to source foam pads or bags like the ones manufacturers use when packaging new Foam Core sheets in cases? I’ve considered trying reinforced Kraft paper rolls (48” from Uline), but I wonder if there’s a more efficient solution—perhaps large protective bags (e.g., 50x96) that substrates can simply slide into.

I’d love to hear your suggestions or insights!

 

[netsol]

we have the same problem. foam core is fragile. the client always seems to send an idiot to pick up, who isn't capable of transporting carefully.

we don't do that many & i am actually glad we don't do more

hopefully there is a good answer to this question, i am watching...

 

[CanuckSigns]

we have the same problem. foam core is fragile. the client always seems to send an idiot to pick up, who isn't capable of transporting carefully.

we don't do that many & i am actually glad we don't do more

hopefully there is a good answer to this question, i am watching...

Yup, the guy who comes to pick up a 4x8 foamcore sign, either in a pickup without a cap and a bunch of tools freely rolling around the bed, or a guy in a Rav 4 that insists it will fit...

 

[Aardvark Printing]

I’m curious to learn what methods you all use to protect 4x8 substrates like Foam Core, Coroplast, or Acrylic until your customers pick them up. Currently, I use a significant amount of shrink wrap after completing a job. While this usually works well, I’ve been doing a lot of work for wedding planners recently, and they tend to be very particular about the presentation and condition of materials.

I also use cardboard pads to sandwich the substrates for added protection, but with rising costs, this approach is becoming less feasible.

Does anyone know where to source foam pads or bags like the ones manufacturers use when packaging new Foam Core sheets in cases? I’ve considered trying reinforced Kraft paper rolls (48” from Uline), but I wonder if there’s a more efficient solution—perhaps large protective bags (e.g., 50x96) that substrates can simply slide into.

I’d love to hear your suggestions or insights!

Wedding planners? May God have mercy upon your soul. I'd rather cut my little finger off with a meat cleaver.
Take a picture before you hand it off and make sure they know it's not your problem once it leaves the shop.
Communication up front is your friend.

 

[Rmurray321]

That’s easy, upgrade them to Sintra, charge more.

 

[czar2178]

We also engage in this process, but I typically handle an average of 90 to 110 full sheets per week for these planners. Additionally, I incorporate custom-cut acrylics, shapes, and prints onto mirror acrylics, which can contribute to congestion in my 15,000 square foot shop before pickup. Occasionally, I encounter errors caused by my careless employees. When I purchase generic foam core (which I rarely do when I am short), it is typically wrapped in foam or plastic sheeting and placed inside the case. Given the prevalence of sign shop owners in our area, I am confident that there exists a simple solution that I am simply overlooking.

 

[hybriddesign]

sometimes we add a sheet of corrugated plastic over the printed side and add plastic corner protectors we get from my binding.com. Sometimes if we’re really worried we sandwich it with two corrugated sheets. $10-20 in material but sometimes it’s worth it

 

[czar2178]

That’s what we currently do but I’m looking for a quicker and more streamlined way to actually wrap them quickly and put them in the pickup slots. Sometimes they forget to pack everything so we have to rip off all the shrink wrap take off the sandwich boards re pack them then use another roll of shrink wrap. A lot of workers are unreliable and I have noticed we tend to do this more than I care to admit.

 

[CanuckSigns]

What about cardboard boxes? When I order foamcore, my supplier will deliver it in a massive 48"x96" x8" cardboard box, I'm sure it's not cheap, but I sounds like it would work and also have a professional presentation for the client.

 

[czar2178]

that would make the most sense but the average order is usually 2-6 Foam boards 3/16 thick so boxing them would not work. I mean we make decent money with these planners but not as much as i make from the franchises i print for or businesses so I am trying to cut costs for these types of jobs to maximize profits

 

[CanuckSigns]

that would make the most sense but the average order is usually 2-6 Foam boards 3/16 thick so boxing them would not work. I mean we make decent money with these planners but not as much as i make from the franchises i print for or businesses so I am trying to cut costs for these types of jobs to maximize profits

Using a standard sized box would save you packing time, which saves you money

 

[czar2178]

I have searched for them and they would need to be custom made as the material is 48x96 and after wrapping the boxes would need at least an inch extra and I can't seem to find them unless I am just thinking of it wrong

 

[White Haus]

that would make the most sense but the average order is usually 2-6 Foam boards 3/16 thick so boxing them would not work. I mean we make decent money with these planners but not as much as i make from the franchises i print for or businesses so I am trying to cut costs for these types of jobs to maximize profits

What kind of magic bullet are you looking for then?

Get your employees to pay attention, start ordering custom boxes/sleeves for your orders, and build that into your cost. (or consider it a wash because you're eliminating wasted labor)

I think the logical step would be to contact a box manufacturer in your area and see what they can work out for you. If you're doing the volume you're claiming, it might justify the expense.

You might not even full stapled cases like the foamcore boxes, you could just get oversized sheets creased so that you can fold them over then a quick tape on the ends to seal it up.

Otherwise, keep doing what you're doing.

 

[White Haus]

I have searched for them and they would need to be custom made as the material is 48x96 and after wrapping the boxes would need at least an inch extra and I can't seem to find them unless I am just thinking of it wrong

You are. Talk to a box manufacturer (local). Tell them what you're trying to do, they'll come up with something for you. Easy peasy.

 

[czar2178]

What kind of magic bullet are you looking for then?

Get your employees to pay attention, start ordering custom boxes/sleeves for your orders, and build that into your cost. (or consider it a wash because you're eliminating wasted labor)

I think the logical step would be to contact a box manufacturer in your area and see what they can work out for you. If you're doing the volume you're claiming, it might justify the expense.

You might not even full stapled cases like the foamcore boxes, you could just get oversized sheets creased so that you can fold them over then a quick tape on the ends to seal it up.

Otherwise, keep doing what you're doing.

Not looking for a magic bullet in anyway. I thought i would give it a shot by asking here to see what everyone else does with similar situations. The cost can be justified but one of the main issues with boxes is I need room for them, this is why i was thinking of some type of roll and finding sleeves hasn't been working for me so far. Using corner protects helps in situations but was mainly trying to get new ideas from other professionals.

 

[White Haus]

Not looking for a magic bullet in anyway. I thought i would give it a shot by asking here to see what everyone else does with similar situations. The cost can be justified but one of the main issues with boxes is I need room for them, this is why i was thinking of some type of roll and finding sleeves hasn't been working for me so far. Using corner protects helps in situations but was mainly trying to get new ideas from other professionals.

I hear ya. We run into the same issue and honestly haven't found a perfect solution. Depending on how they're being shipped and the value of the job, a lot of times we'll just use full sheets of coroplast and slit pieces to protect the edges.
Not ideal when you're using $25 worth of material to pack an order but I'd rather that than have an order get damaged, especially if it's shipping with a carrier and for a good client.

I'm sure you could get something from a box manufacturer. Oversized sheets that have been pre-creased (not folded) so the can be stacked flat. Worth looking into.

Or at the very least oversized sheets of corrugated, and you do your own creasing etc.

 

[czar2178]

I hear ya. We run into the same issue and honestly haven't found a perfect solution. Depending on how they're being shipped and the value of the job, a lot of times we'll just use full sheets of coroplast and slit pieces to protect the edges.
Not ideal when you're using $25 worth of material to pack an order but I'd rather that than have an order get damaged, especially if it's shipping with a carrier and for a good client.

I'm sure you could get something from a box manufacturer. Oversized sheets that have been pre-creased (not folded) so the can be stacked flat. Worth looking into.

Or at the very least oversized sheets of corrugated, and you do your own creasing etc.

Unfortunately we do the same lol. I just ordered 48"x1250' Air Foam Rolls and 48" reinforced Kraft sheet paper to see if those will solve the issue. If this fails then I guess the box route is my only option. Now I need to go find a bigger building LMAO

But I really do appreciate the feedback so far and it does seem like we are all on the same page it just sucks for us wide format printers when working with full sheets of rigid substrates

 

[White Haus]

Unfortunately we do the same lol. I just ordered 48"x1250' Air Foam Rolls and 48" reinforced Kraft sheet paper to see if those will solve the issue. If this fails then I guess the box route is my only option. Now I need to go find a bigger building LMAO

But I really do appreciate the feedback so far and it does seem like we are all on the same page it just sucks for us wide format printers when working with full sheets of rigid substrates

Absolutely, it definitely is a frustrating part of the business.

We also stock 48" foam and 48" corrugated b flute rolls, but of course it's not quite wide enough to cover the edge. There may be 60" rolls somewhere out there but harder to come by.

 

[czar2178]

I am sure there is but i am going to layer them off center on both sides and just tape it shut as a quick test and if it works correctly then I will find wider rolls or just have them custom made since I go through a lot of boards daily, this is also a good test because I am considering delivering these signs once I can find halfway decent drivers

 

[Superior_Adam]

We use the perforated foam rolls from uline. We also tell the customer that once it leaves the shop we are not responsible for damage due to their handling and transport. If large sheets we let them know they will need a full size truck with nothing in the bed and something to support it since it will hang out.