Our Crating Process

All our equipment is being packaged in crates, using pallets and heavy-duty packaging material, depending on the product being prepared for shipping. Here’s how our crating process works.

Step 0: Palletizing Equipment

We place the equipment in a custom-built pallet made by our team. The bottom of the pallet is built with 1x4s, then 2x4s horizontally to give a 4-inch space for forklifts and pallet jacks to get under. It mixes 1x4s, plywood, and both, depending on the weight of the equipment.

Step 1: Preparing the Equipment

Now, we prepare the equipment for the construction of the crate. This involves protecting it with blankets, foam wrap, boxes and wooden blocks. Products packaged in boxes or crates are secured with a strapping machine but we ensure they are not overtightened. We put the heavier products on the bottom, with several layers of heavy-duty stretch wrap on both sides and around the boxes. If the machine is a large frame piece, it is securely tied with polyester woven fabric and other materials, which are used to make the treadmill belt. This material prevents scratches.

Step 2: Constructing the Crate (Gathering 2x4's)

Immediately the equipment and all its components have been wrapped and prepared, we start with building the crate.

Step 3: Constructing the Crate

Our team uses a nail gun to secure four 2x4s vertically at each corner of the pallet, which allows us to set up the sides of the crate.

Step 4: Constructing the Crate (Adding Horizontal 2x4’s)

Using a ladder, nail gun and more 2x4s, we can connect the top with the vertical 2x4 posts to create a cube built around the equipment.

Step 5: Constructing the Crate (Adding Diagonal 2x4’s)

We also connect another set of 2x4s diagonally to the frame posts. This improves the structural integrity and guards against shipping damage. We use plywood over fragile areas like the consoles on cardio products.

Step 6: Cover and Protect the Crate w/Stretch Film

Our team will cover the crate with stretch wrap. We ensure every aspect of the crate is covered with stretch wrap which prevents dust and debris from getting in during transit. But why do we use clear stretch wrap? That’s because it allows warehouses and truck drivers to see that it's fragile exercise equipment, prompting them to handle the products with care.

Step 7: Measuring the Crate

Our next step is to measure the crate, which ensures that it meets our shipping specifications. We make sure that it fits the transportation requirements.

Step 8: Labeling the Crate

Finally, we clearly add a label to the crate, which makes it easy to identify and track the equipment.

Materials Used

7/16” OSB Plywood
2” x 4” x 8’ Lumber
1” x 4” x 8’ Lumber
Stretch Wrap
Nails w/Nail Gun
Polyester Woven Fabric (To Secure / Strap the equipment to the pallet)
Blankets / Boxes / Foam Wrap (Wraps / Protects)
Measuring Tape
Marker