(L-R) Palletcap inventor Hayley Shirley demonstrates the cost-effective new Eco-Cap to long time customer Andy Mitchell.

The Staffordshire inventor who claims his cardboard cone has saved the global materials handling industry millions in damaged stock has launched a new, cost-effective version of the Palletcap.

Inventor and former pallet distribution manager Hayley Shirley says with over 750,000 Palletcaps sold, the product's manufacturer can now achieve economies of scale for companies who bulk buy the product.

"We have achieved this by removing much of the outer packaging, and reducing flood printing and labour costs," Shirley explains.

Eco-Cap, selling for 45p (USD0.73) a unit, is a new version of the cardboard cone which, when stacked on pallets, provides a visual warning and physical obstacle to accidental stacking on fragile goods.

The new product has been trialled with a variety of Palletcap users, including distribution specialist Mitchells of Mansfield.

Managing director Andy Mitchell says the Eco-Cap has saved the company money and has proven to be every bit as effective as the Palletcap.

Shirley estimates the original 62p (USD1) cardboard cone has saved the global materials handling industry an estimated GBP40 million (USD64.8 million) in damaged stock. It is now a familiar sight in warehouses worldwide and has won an array of awards including the Fork Lift Truck Association's 2005 award for excellence in safety (Forkliftaction.com News #222).