Inside the Custom Case Design Process: Navigating Regulations and Client Research

Q&A with James Egloff, Chief Operating Officer & Chris Egloff, VP of Strategic Business Opportunities

Question #1: Can you walk us through a typical case design process?

When we take someone through a case design process, it’s essential to gather all pertinent information needed to make an informed decision about the product that best serves the customer’s needs. It’s not just about the size, weight, and shape of the object; it’s about understanding all the challenges involved to ensure that the case or custom solution we create is perfectly tailored to the specific requirements.

You can buy off-the-shelf products, but our approach involves asking deeper questions, such as: What doorways will you be navigating? What facilities will the case be entering and exiting? Will the case primarily be used indoors or outdoors? Is it near salt water or exposed to harsh environmental elements? Each of these details is critical in helping us consult accurately and create packaging that meets all functional needs.

Once we gather this information, our in-house engineering team turns client requests and preferences into practical solutions. We design a solution that balances cost-effectiveness and functionality, offering options like value-engineered designs for clients focused on budget, or more specialized solutions for unique needs. Our team is equipped to produce designs that are replicable for quick turnarounds or structured for durability, depending on the requirements. We meticulously address every detail to provide the best possible solution.

Americase stands apart from other manufacturers. While many container makers produce standard sizes for catalog offerings, at Americase, we approach each project as a complete solution, addressing the client’s specific problem from start to finish. We consider environmental conditions, size, usage, and transport requirements to ensure that the case meets all functional and regulatory needs.

The timeline for our cases depends on the client’s needs. For straightforward designs, we expedite production to provide a solution quickly. For specialized requirements, such as fire containment or environmental protection (e.g., pressure or temperature control), we may extend the timeline to ensure rigorous testing and compliance with client specifications. This thorough testing gives clients confidence that the case will meet their precise needs and regulatory standards upon delivery.

Question #2: Have regulations significantly changed any of your processes over the last five years?

Regulations have significantly impacted our processes over the past five years. Adhering to these standards involves attention to every detail, from labeling size and color to specific pictograms required for hazardous materials. Our expertise ensures that clients are always in compliance, minimizing the risk of delivering non-compliant products.

Americase stays updated on current and future regulations. We are members of key organizations, such as COSTHA (Council on Safe Transportation of Hazardous Articles) and PRBA (Rechargeable Battery Association), allowing us to actively contribute to regulatory discussions and help shape regulations that are being writtens. We also work with international bodies like the UN and IATA to influence regulations affecting the transport of dangerous goods. These partnerships help us anticipate and integrate regulatory changes, ensuring our products remain compliant in the long term.

One example is our involvement in discussions around lithium battery regulations. Lithium batteries vary greatly in chemistry and safety requirements, which means packaging standards must be precise to manage risks like thermal runaway. Our team actively participates in working with SAE G-27, to develop safe packaging that would allow for high-charge lithium batteries to be transported by air, which is currently embargoed.  We are also working with SAE J3303 on writing regulations for safely storing lithium-ion batteries.

Question #3: What is the research and discovery process like with your clients who need custom cases?

The research and development process is a cornerstone of our work. Whether it’s working with aerospace, oil and gas, or data center industries, our R&D approach is client-focused and thorough. For example, in the oil and gas sector, where equipment is often subjected to rough handling and harsh environments, we design cases to withstand extreme conditions, including G-Force testing, submersion, and climate exposure.

Our R&D team’s capabilities are extensive, ensuring we can address any challenge that arises. For instance, when NASA needed a solution for an oxygen cylinder aboard the International Space Station, we collaborated with them to create a case that could withstand high-pressure releases without causing damage. This required extensive testing and innovation to meet stringent safety standards.

At Americase, our approach is not about selling a generic container. Instead, we offer our expertise, customization, and decades of experience to meet unique client needs. Many clients come to us thinking they need a standard box, but through our consultative process, they realize they need a complete solution. We ask critical questions that reveal the true requirements, ensuring the final product serves its purpose effectively, whether it’s protecting a high-value item, adhering to strict regulations, or facilitating complex logistics.