Brown Jordan International has developed a patented technique for packing outdoor furniture for shipment that the company said is drastically cutting freight costs of its Isabella La-Z-Boy collection.

The new packing method has been used over the last few months to ship its Isabella La-Z-Boy collection, resulting in reduced total freight costs of nearly 50 percent.

“Previously, we were spending a whole lot of money to ship to America,” said Chris Carmicle, president of Brown Jordan International’s national accounts division. “We used to get 15 to 16 sets in a container. Now, with the removal of the sofa skirt, we’re getting 30-40 pieces.”

The key element of the freight- and space-saving loading technique is the way that the furniture is positioned in a smaller box, utilizing space more effectively. It involves removing the skirt—or bench—of a loveseat, then sliding in the accompanying chairs and pillows in the same box.

“There used to be a sofa box, plus two lounge chair boxes,” Carmicle said.

When the customer receives the fully assembled sofa, they re-attach the skirt and lineup the pillows on the couch.

Also, the new packing technique requires 30 percent less packing materials such as styrofoam, tape, cardboard and plastic, than traditional packaging, according to the company.

Carmicle added that “a few things are in development that will probably be put into place,” to further utilize the space-saving packing technique.