Multi-material crate design for modern data server infrastructure
When a $200B+ global technology company set out to launch their next-generation data servers, they turned to TransPak for more than just packaging; they needed a strategic design partner.
The challenge was clear: modernize a crate design that had gone unchanged for over 30 years. The goal was to improve efficiency, reduce material usage, and create a packaging solution that could streamline deployments across global data centers.
Packaging Solutions to Support Sustainability Goals
TransPak’s Trumbull, Connecticut team took the lead on the project, collaborating closely with the customer’s engineers and supply chain stakeholders. Over the course of a year, our engineering team developed a fully redesigned crate capable of housing all components of a data server rack in a single crate.
Beyond meeting the customer’s core requirements, the team introduced several thoughtful enhancements: a custom pocket for the server’s access panel, built-in space for a field ladder, and a base designed to minimize foam use. Instead of traditional full-foam interiors, the crate features minimal foam placed strategically along the sides.
The result is a packaging solution shaped by decades of engineering expertise and a multi-material approach—designed to reduce waste and meet the demands of today’s data infrastructure.
Executing at Scale with a Global Team
Production ramped up in spring 2025, with crates being manufactured daily at TransPak Trumbull. Each unit undergoes rigorous inspection to ensure consistency, precision, and reliability at scale.
To meet the demands of this complex program, TransPak deployed a global support model. Engineering resources in Texas collaborated with operations teams in Connecticut, while our Monterrey, Mexico facility provided subassembly support to maintain production flow and shorten lead times. We also managed sourcing of custom materials to align with the exact specifications and performance needs of the product.
Built on Partnership, Powered by Expertise
This project highlights TransPak’s ability to deliver integrated solutions. It also reflects the strength of long-term partnerships. When it came time to reimagine their packaging in North America, the customer turned to a team they already trusted.
With 24 employees currently on site, half of whom are dedicated full-time to this project, TransPak Trumbull is delivering a high-impact solution with precision, speed, and pride.
Engineering from Concept to Crate
At TransPak, we don’t just build crates; we engineer solutions that move the world’s most advanced technology forward.
From safeguarding fragile components in transit to optimizing reusability and recyclability, our team thinks through every detail, so your packaging works seamlessly across production, shipping, and beyond.
Ready to see what’s possible? Visit transpak.com/design to learn how our engineers can support your next launch.
