Transporting oversized equipment presents a unique set of logistical challenges. Whether it is a 90-inch display screen, a motorsport body panel, or a piece of sensitive industrial machinery, standard off-the-shelf packaging simply isn’t an option. You need a solution that offers immense structural integrity without becoming impossible to move.
At PottertonPacs, size is no barrier to excellence. As leading UK manufacturers, we specialise in the design and construction of large flight cases and heavy-duty road trunks. We build the “giants” of the protective case world, ensuring that your biggest assets receive the same precision protection as your smallest components.
Engineered for Strength and Stability
Building a large case requires more than just making a standard box bigger. As the dimensions increase, the structural engineering must adapt to handle the increased weight and torque.
We utilise premium materials to ensure rigidity and durability:
• Heavy-Duty Plywood: We use high-grade 9mm or 13mm birch plywood with rugged laminates for maximum impact resistance.
• Rigidified Aluminium: For superior strength-to-weight ratios, our aluminium skins resist puncture and corrosion.
• Reinforced Hardware: Our large trunks feature heavy-duty ball corners, recessed butterfly catches, and bracing to ensure the case holds its shape under stress.
For scenarios where weight is a critical concern such as air freight we also manufacture large cases using Astroboard. This advanced polypropylene honeycomb material reduces the case weight by up to 40% compared to traditional timber, without sacrificing strength.
Mobility Solutions: The Warehouse on Wheels
A large flight case is useless if you cannot move it. Mobility is at the heart of our design process for oversized units.
We equip our large cases with industrial-grade 4-inch castors (swivel and braked) capable of supporting hundreds of kilograms. For extremely heavy loads, we install skid plates or pallet bases to allow for easy lifting by forklifts.
We also design for accessibility. Loading a 100kg server rack or a mixing console into a case shouldn’t cause a back injury. We can integrate:
• Removable Front Panels: For “lift-off” access.
• Loading Ramps: Built into the door for rolling heavy gear straight in.
• Gas Struts: To assist in opening heavy lids safely.
Bespoke Interiors for Oversized Items
The danger with large containers is the “rattle factor.” If a large item moves inside a large case, the momentum can cause catastrophic damage.
PottertonPacs eliminates this risk through custom foam engineering. Our design team uses CAD technology to map the exact geometry of your equipment. We then use CNC routing to create large-format foam inserts that brace your equipment at its strongest points. Whether you need a simple felt lining to prevent scratches or complex, multi-layered Plastazote foam for shock absorption, we ensure a perfect, snug fit.
Trusted by Industry Giants
From storing exhibition stands and lighting rigs to protecting medical scanners and defence hardware, our large flight cases are the backbone of British logistics.
When the equipment is too big, too heavy, or too valuable to fail, trust PottertonPacs to deliver the solution. We build the cases that keep British industry moving.
Have a large project in mind? Contact our Leicester design team today to discuss your dimensions and requirements.
