Radiation Safety Products Manufacturer - Case Study

A radiation safety products manufacturer launched a new line of lead shipping pigs (also known as shipping pots or containers) used to transport nuclear medicine for cancer treatments. Because these materials are highly sensitive and time-critical, each shipment must arrive securely and intact at medical facilities across the country.

To support customers nationwide, the manufacturer wanted to offer an all-in-one packaging kit that included the lead pig, protective inserts, and a corrugated shipping box. Lead pig dimensions vary slightly between customers, and even small differences can impact load stability and protection. The packaging solution needed to securely hold multiple pigs per box while preventing movement or damage during handling and transit.

Goals:

• Secure lead pigs during shipment to prevent movement or damage
• Source a foam insert solution that fits multiple pig sizes
• Minimize upfront tooling costs while maintaining package integrity
• Standardize packaging components for consistency and efficiency

Rocket Industrial partnered with the manufacturer to source a custom foam packaging solution that meets the strict protection requirements of nuclear medicine shipping. After reviewing how the products would be shipped and handled, Rocket identified a modular packaging approach that delivers reliable protection while keeping costs manageable.

Key elements of the solution included:

• Using two standard plastic corrugated box sizes to eliminate the need for new cutting tools
• Sourcing interlocking EPS foam inserts to hold four lead pigs per box and prevent movement
• Using hot wire–cut foam for lower-volume production to avoid expensive die setup costs
• Adding customer branding through digital printing

This approach significantly reduced tooling expenses while ensuring the packaging could scale efficiently as customer volumes grow.

• Custom foam inserts that securely hold four lead pigs per box

• Improved protection for nuclear medicine shipments

• Reduced upfront tooling and packaging costs

• Scalable packaging solution designed for future growth

Rocket Industrial delivered a packaging solution that enables the manufacturer to safely ship nuclear medicine used in cancer treatments with confidence, while allowing the packaging to scale and accommodate additional product sizes in the future.