Challenge details:

Edible salt is transported in large volumes from the manufacturing plant to multiple packing centers across the country, with 99% of the movement dependent on rail due to its extensive reach and cost‑effectiveness. Currently, 90% of the salt is packed in 50‑kg bags that are manually handled inside railway wagons, resulting in a high number of individual handling units and significant operational complexities. This manual process creates challenges in loading and unloading, especially given the large volume of bags involved. Although 1500‑kg jumbo bags are available, they cannot be used in railway wagons due to handling constraints and door‑size limitations, while shifting to containerized transport would be substantially more expensive. Therefore, there is a strong need for an alternative packaging format that can be handled using small forklifts, reduces manual labor, and remains compatible with the rail wagon door width of 1200 mm (with an ideal container width of ≤1 m). The preferred filling capacity ranges from 50 kg to 150 kg, ensuring the solution remains manageable at both origin and destination points.

We are seeking an innovative, sustainable, efficient, and food‑safe packaging solution that can replace the current 50‑kg bags and enhance handling efficiency within a predominantly rail‑based supply chain. The packaging must protect hygroscopic edible salt from moisture ingress, support forklift or mechanical handling where possible, and enable smoother loading and unloading inside rail wagons. The solution may be reusable but should ideally support reverse logistics, including collection, cleaning (where applicable), and return to the manufacturing site. Collapsible or foldable designs are preferred to reduce return‑transport costs.

The objective is to identify a scalable packaging alternative that reduces manual handling effort, improves operational efficiency, maintains product integrity, minimizes plastic use through reuse, and delivers an environmentally responsible approach for the large‑volume movement of edible salt.