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New FlexyCell packaging concept delivers customised packaging at low cost

Conteyor : 27 October, 2006  (New Product)
FlexyCell is a customised packaging concept with many of the advantages of standard packaging systems, such as low cost, short delivery times, no tooling costs and suitability for small volumes. It has been developed by conTeyor for the business-to-business market for applications where components must not be scratched, damaged or broken, yet are easily accessible for the customer to load or unload.
conTeyor FlexyCell is a dunnage product that can be incorporated into almost any type of handling unit like a plastic box or plywood crate, ranging between 1,200mm (l) x 1,000mm (w) x 1,200mm (h) to 200mm (l) x 200mm (w) x 10mm (h). Each unit of FlexyCell comprises an array of elliptical pockets in a honeycomb cell structure, with each pocket normally holding one component.

“The FlexyCell units are designed for repeated use and can be used for the protection of similar, if not identical, components,” explains Patrick Hugenholtz, managing director of conTeyor Multibag Systems NV. “The diameter of the cells can vary from 20mm up to 1,000mm and the height - equal to the height of the component - between 10mm and 1,200mm.”

“FlexyCell offers the unique combination of allowing the end-user to configure their own specially designed packaging on the internet ( with all the advantages of standard packaging,” explains Patrick Hugenholtz. “This is a new product that will allow customers to customise packaging for markets such as automotive, cosmetic, electrical/electronic, medical, etc at competitive cost to standard packaging systems.”

The FlexyCell dunnage system prevents components from touching each other and from moving inside their container, which usually is supplied by the customer. FlexyCells do not have a bottom or top; semi-rigid, textile-covered, plastic sheets are used as separators at the bottom, top and between multiple units of FlexyCells within a single container. The different layers are stacked on top of each other.

Produced from high quality, non-woven textiles, FlexyCell is thin (approx 0,3mm wall thickness), lightweight, dust-free, completely recyclable and it can even be anti-static.

The two types are either TK, a Tyvek material with excellent durability and protective characteristics (based on PE), or DL01, which is less stiff and intended for single-layer designs where price is at a premium (based on PP). Neither material can be easily torn and both have a high resistance to abrasion. Customised text and numbers can be printed on both the FlexyCells and the separators.

The design is so simple that customers can configure their own packaging systems on-line (at The website will present the customer’s design in 3D after the dimensions of the component and the container are entered. Optional text, such as part number, can be entered, after which the website will show the price immediately!

If the price and the design of the FlexyCell are to the customer’s expectation, it can be purchased on-line.

One of the great benefits of the conTeyor system is that FlexyCell customised packs can be designed and delivered within 2-3 weeks. This compares with 6-8 weeks for conventional packaging and is obviously a major improvement.

When the FlexyCell is delivered, the customer has only to expand it manually and insert it into their container and start loading.

This new packaging concept was developed by conTeyor in response to customer demand for a customised system that is cheaper than existing techniques and with much shorter lead times. FlexyCell delivers on both counts. Its cost is only 20-30% that of typical returnable packaging and very similar to that of one-way packs. It is also particularly cost-effective as there are no special tooling costs.

In practice, FlexyCell’s light weight and high flexibility coupled with its ability to be customised allows more components and products to be packed than other expandable products, having a major positive impact on transportation costs. Also, the empty dunnage is very easy to handle and takes up little.
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