The Challenge
An Electronic Manufacturing Services (EMS) provider in Pune was trapped in a costly logistics bind. The manufacturer shipped high-volume, low-density printed circuit board (PCB) assemblies to an OEM in Bangalore — but the economics worked against them at every turn.
Because PCB assemblies are lightweight but bulky, standard PTL providers billed them at high volumetric weights using the standard formula:
Fearing transit damage from double-stacking of fragile PCB boxes, the manufacturer had resorted to booking dedicated FTL trucks that ran only 50% full — dramatically inflating logistics spend while solving only the damage problem, not the cost problem.
The Intervention
DNS stepped in as the strategic PTL logistics provider, design-engineering a custom cargo consolidation plan that solved both problems simultaneously.
- check_circleDNS introduced standardized, reusable stackable cages that protected fragile PCB boxes while enabling double-deck loading — eliminating physical weight transfer onto the components.
- check_circleWith damage risk removed, DNS consolidated shipments into daily scheduled Express PTL container runs on the Pune–Bangalore route — no half-empty FTLs, no volumetric billing penalty.
- check_circleDirect ERP integration automated GST e-way bill generation and validation, eliminating manual compliance errors ahead of the June 2026 GSTN updates.
The Quantified Results
"The engineering insight was simple but powerful: if you eliminate the physical risk of double-stacking, you unlock PTL economics for fragile goods. The stackable cage was the entire solution."