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Case Study: Export Packing of Industrial Robots for Loop Technology
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Client: Loop Technology Ltd – Industrial Automation & Robotics Specialist
Service: Export Packing & Logistics Advice
Shipment Route: United Kingdom → North America
Overview
Loop Technology asked John Pipe International to handle the export packing and containerisation of two high-value industrial robots, one of which is the largest industrial robot in the world by weight and reach. The equipment was being shipped to a major aerospace manufacturer in North America and represented a significant investment. The shipment needed specialist handling, full compliance with international shipping standards, and reliable protection during the journey.
Project Requirements
The packing and logistics needed to meet several essential criteria:
- Protect sensitive robotic components during ocean transport
- Comply with ISPM-15 standards for all timber packaging
- Ensure safe and efficient handling at the UK point of departure
- Keep downtime to a minimum so Loop Technology’s project timeline stays on track
Our Approach
With over 60 years of experience, John Pipe International delivered a full end-to-end packing and logistics solution.
1. On-site Assessment & Planning
Our technical team carried out a full on-site review, considering:
- Two of the largest robots in the world, including one weighing 12.5 tonnes
- 44 metres of robot rail with individual sections weighing over 2 tonnes
- Bespoke end effectors (FibreFORM and FibreEYE) used for advanced carbon-fibre aircraft component production
- High-value electronic and control equipment
- Vibration-sensitive joints and servo motors
- Multiple-axis robotic arms that required secure, fixed positioning
- Moisture- and corrosion-sensitive components needing environmental protection
- Large track sections, sub-assemblies and various ancillary parts
2. Custom Crating & Protection
To protect every item during the journey, we:
- Designed and built 22 bespoke ISPM-15 timber cases, sized and structured for General Purpose Shipping Containers
- Created vapour-barrier moisture protection using barrier bags and desiccants
- Added tailored internal supports to prevent movement
- Loaded a total of 14 containers with precision block-and-brace methods
3. Compliance & Documentation
All crates and components were marked and labelled according to international handling, lifting, and orientation standards to ensure smooth global transit and customs clearance.
4. Transport & Coordination
The on-site packing and loading were carried out at the customer’s facility, ensuring minimal disruption. All items were block-braced and secured to withstand the full journey to North America.
Outcome
The shipment was delivered on time, arrived in perfect condition, and met all import and handling requirements.
- Installation in North America began exactly on schedule
- No damage, delays, or compliance issues were reported
- Both Loop Technology and the aerospace manufacturer praised the quality and reliability of the packing
Client Feedback
“This was a critical shipment for us. The robotic system arrived in excellent condition, and we were able to commence integration with no delay, ensuring the project timeline was maintained. The quality of packing, flexibility and professionalism shown by John Pipe International exceeded expectations. The whole team at John Pipe delivered exceptional quality, customer service and value.” — Project Engineer, Loop Technology
Key Takeaways
- Complex, high-value robotic systems need precise planning and specialist export packing
- John Pipe International reduces project risk through experience, attention to detail and global compliance knowledge
- Clients in regulated sectors such as aerospace can rely on JPI for safe, efficient, and compliant international shipment handling
Find Out More
To learn more about our export packing services or request a tailored quotation, please visit:
https://www.johnpipe.co.uk/contact
Looking for help with shipping?
Contact me directly at sarah@johnpipe.co.uk
Established in 1961 and employing 40 people, with an annual turnover exceeding £5m, John Pipe International has been partnering with manufacturers and exporters of goods in the south west and beyond for over 60 years. While the majority of our customers are based near our two branches in Dorset & Hampshire, our reach does extend to all of the UK and even abroad. As Export Packers and Freight Forwarders, we have packed and shipped any product you could imagine. From tiny screws for airplanes, to huge cheese making machines for the dairy industry. You name it, we have probably packed and shipped it.
We manufacture bespoke wooden and cardboard boxes for our customer’s goods, secure the items within these boxes and arrange the onward shipping. Of course, some of the products we support our customers with, take planning, packaging design work and additional lifting resources, such as cranes and, as you might expect, careful routing. So far the largest wooden box we have made is 12 x 4 x 4 metres. The heaviest item we have shipped?… 40 tonnes.
It is not unusual for JPI to be asked to design bespoke packaging for a particular item or kit of parts, conforming to a set of criteria set by the end user. At JPI we excel at this, having designed and packaged items from any industry you care to mention. And not every packaging design is a box…
The Challenge
Design a Cable Drum that meets the following requirements:
- Capable of holding 95m of cable (100 Kg approx.)
- Completed solution needs to be weatherproof.
- Sheathed to protect cables while cable drum is rolled from one point to another.
- Sheathing to be removable without the use of tools.
- Capable of winding a cable onto the drum, without the requirement for additional equipment.
- Possible to move from one point to another, without use of mechanical aids.
Our drum survived the testing, confirming that we had designed a solution that could bear the required weight of cables that it would be used for.
The Solution
Using strong plywood and timber pieces, we have created an incredibly strong storage solution. At a testing event, we loaded twice the amount of cable onto our drum and repeatedly rolled it up and down high kerbs and over uneven ground to replicate the harsh handling it would receive.
Our drum survived the testing, confirming that we had designed a solution that could bear the required weight of cables that it would be used for.
To make the drum weatherproof, every part of our solution is painted or greased to protect it.
A shroud made of slats of timber, joined together with webbing that can be secured around the flanges of the drum and secured by hand tightening a wing nut provides the required outer protection without the need for tools.
By creating a drum within two wider outer flanges (effectively a drum within a drum), we made it possible for a cable to be wound on by spinning the inner drum, while the outer flanges were stationary. The wider outer flanges make it possible for the cable drum to be rolled around, enabling the drum to be moved from place to place without the need for mechanical aids.
Rotating around a specially created spindle with bearings, the weight of the cable was not an issue, and one person could easily spin the inner drum to wind the cable on or off the drum.
The Benefit
Our customer is looking for a practical solution to overcome the difficulties they had experienced in the past. This relatively low-cost solution matched their requirements perfectly. Furthermore, as the solution is made from wood it is noted that empty drums are easily recycled when no longer required.
A shroud made of slats of timber, joined together with webbing that can be secured around the flanges of the drum and secured by hand tightening a wing nut provides the required outer protection without the need for tools.
The wider outer flanges make it possible for the cable drum to be rolled around, enabling the drum to be moved from place to place without the need for mechanical aids.
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Our Services:
How we can help...
For sixty years, John Pipe International have been a diligent provider of export services. Based in the South of England, we are fully equipped to handle your export packing and freight needs. Whether you’re shipping overseas or packing dangerous items, our team are on hand to assist with the logistics of your project. With our MPAS certification, we are happy to assist with military and defence exports.
Management team
It takes a dedicated team to manage global logistics. The John Pipe International management team have years of experience and background knowledge. Find out more about the people who will manage your export project.
Nathan Kennedy
Managing Director
Nathan was approved by the MoD as a Military packaging designer in 2012, after qualifying as a Military packaging professional. Coupled with his Dangerous Goods in Transit qualification, Nathan can apply this knowledge and experience to ensure any goods are packed in tried and tested containers.
Jon Felton
Director
Jon is the Works Director at the Hampshire branch. He has been a logistics professional for over 25 years and has held management positions in the fast-moving consumer goods (FMCG) industry. This has allowed him to build strong customer relationships and offer a comprehensive service package for packing and shipping to our clients.
