How We Protected Four Oversized Architectural Pieces with One Custom Crate

When transporting oversized architectural components, the biggest challenge isn't always the size. It’s the risk every time it changes hands.

Every additional component means another item to handle, another opportunity for damage, another piece to keep track of, and another potential delay on site.

For Ardec Group - a leading supplier of Canadian-made handwashing solutions for commercial and public washroom spaces - finding a smarter way to transport large, valuable fixtures was a top priority.

Their project involved transporting two large mirror-image sinks, each made up of separate basin and countertop sections that would later be assembled on site.

And the turnaround time was super tight. This is where we came in.

What were we looking at? Four large, delicate components and one tight deadline.
And for us: one opportunity to get everything there safely.

Here's how we delivered a custom crating solution that simplified and secured the entire process.

The Challenge: Four Components. One Delivery.

Large architectural fixtures aren't easy to transport.

Not only are they often oversized and fragile, but many arrive on site in multiple sections that all need to remain protected throughout the journey.

For Ardec Group, every one of the four sink components needed to arrive in perfect condition before installation could begin.

Shipping each section separately would have meant:

• More handling throughout the supply chain
• More opportunities for damage
• More complex logistics
• Increased shipping costs
• Greater risk of delays during installation

On top of that, the project had a fast turnaround, leaving little room for error.

The SmartShield Solution

Rather than designing four separate packaging solutions, our engineering team looked at the project differently.

Could all four components travel safely together?

The answer was yes.

We designed and manufactured one custom wooden crate engineered specifically around the dimensions of every sink section.

Inside the crate, a 48-piece custom foam set was engineered to support the sinks at critical load-bearing points and brace them securely in position throughout transport.

Manufactured from 4-inch, black polyethylene (PE) foam and precision cut on our in-house waterjet, the foam components were designed to minimise movement while protecting the sinks during handling and shipping.

Eighteen of the foam pieces were permanently bonded into the crate, while the remaining sections acted as removable filler blocks, installed alongside the sinks to provide additional support and maintain secure positioning throughout the journey.

Together, the custom timber crate and engineered foam supports allowed all four sink sections to travel safely in a single shipment, simplifying logistics, helping optimise freight efficiency, and reducing the risk of damage.

Why One Crate Made a Difference

Often the smartest packaging solution is the simplest - and one that removes unnecessary steps.

By consolidating four oversized components into one custom crate, we helped:

• Reduce handling throughout the supply chain
• Lower the risk of accidental damage
• Simplify loading and unloading
• Improve shipping efficiency
• Keep all project components together for installation
• Meet the customer's accelerated project timeline

Instead of managing four separate shipments, Ardec Group had one complete packaging solution designed specifically for the application.

Custom Packaging Starts with the Product

No two architectural projects are the same.

They all have different dimensions, materials and installation requirements.

It’s why our team engineers every packaging solution around the product itself

Whether it's oversized architectural fixtures, aerospace components, medical equipment, defence applications, or industrial machinery, our goal is always the same: Create packaging that protects products while making transportation, handling, and installation easier.

The Results

Thrilled to say the finished packaging solution for Ardec delivered:

• Four oversized components consolidated into one custom crate
• 48-piece custom foam system engineered to minimise movement during transport
• Reduced handling throughout transportation
• Lower risk of shipping damage
• Improved shipping efficiency
• Fast turnaround to support the project schedule

Most importantly, every component arrived together, ready for on-site assembly.

Client Testimonial

Happy clients make us happy.

"The SmartShield team's quick response times, combined with their invaluable expertise in designing custom packaging, makes the ordering of our custom crates a seamless process."

Nathan Smith, Sales Manager, Ardec Group

Protect More Than your Product

Every oversized shipment brings its own challenges.

Whether you're transporting architectural fixtures, construction components, or complex assemblies, SmartShield designs custom packaging solutions that reduce handling, simplify logistics, and help valuable products arrive ready for installation.

Talk to our team about custom crating