A major US shipping company, our largest client, has been working with us for over three years. Their operations include both maritime container transport and truck transport from ports to factories. They require high-strength, multi-functional covers for 10ft, 20ft, and 40ft standard containers.
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· Covers must withstand harsh marine conditions (salt, corrosion) as well as high-speed road transport (wind load, rain, UV).
· Traditional container covers are time-consuming and labour-intensive to install/remove, leading to high labour costs and risk of worker injury.
· During transport, workers need quick access to container information while ensuring ventilation to prevent moisture build-up – without letting water inside.
· The client required durable covers that can be reused many times to reduce long-term operating costs.
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From initial discussions to final design approval, the process took six months. We worked closely with the client through multiple drawing revisions and sampling tests, eventually settling on a zipper + Velcro composite structure with several innovative features:
1. Roll-up door at the front end
A roll-up door was designed at the front of the container cover, allowing easy loading and unloading. When not in use, the door can be rolled up and secured without taking extra space.
2. Document pocket
A dedicated document pocket is sewn onto the cover to hold shipping papers, customs documents, etc., keeping them with the container and preventing loss.
3. Transparent window
Transparent PVC windows are placed at key positions, allowing workers to read container numbers, barcodes, and other information without opening the cover – greatly improving yard efficiency.
4. Automated installation/removal tooling system (revolutionary innovation)
To address the client’s biggest pain point – low efficiency and high injury risk of manual handling – we designed and manufactured over 200 sets of specialised tooling. This system enables automated installation and removal of container covers. It significantly reduces labour costs, eliminates worker injuries caused by working at height or handling heavy loads, and cuts installation/removal time by more than 70%.
5. Ventilation system
Ventilation holes are strategically placed to ensure air circulation inside the container, preventing the cover from ballooning or tearing due to air pressure build-up during high-speed road transport. The vents are rain-proof, so water cannot enter the container during wet weather, effectively preventing moisture damage.
6. Durability design
The cover is designed for a service life of 3 years or 20 reusable cycles, balancing longevity and replacement cost for the client.
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· Total orders exceeded 100,000 units, covering 10ft, 20ft, and 40ft standard containers.
· The client has adopted this solution as a standard specification for their global fleet of ships and trucks.
· The tooling system has been rolled out across multiple ports and logistics centres, resulting in a significant drop in workplace injuries and earning internal recognition for efficiency gains.
· This project has become our benchmark case for container covers, attracting inquiries from other shipping and logistics companies worldwide.
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