The brief from the customer to carry out a complete re-design of the current pack which uses a corrugated outer carton with foam inserts. The customer asked, if possible, to have a solution made from 100% recyclable corrugated. It also must pass a one metre drop test which was on all flat faces, corners and two edges. It is a pack that is also exported through road and sea.
The new solution consists of an outer 0201 carton made from BC200KT, printed with the customers logo. This includes four corrugated die-cut corner fittings made from BC300KK (12S/C) along with a die-cut top accessory tray made from BC200KT. Each part is supplied flat to the customer mainly for onsite storage benefits. The inner fittings are designed with features that allow them to easily be folded and secured into position with innovative locking features.
Packs and product are despatched from the UK across Europe by road and sea, and this is why the drop test was so important. Several drop tests took place, across 6 flat faces, 2 edges and 2 corner drops, and the pack and product passed them all. It is worth mentioning that many competitors had attempted a fully corrugated redesign before but had always failed at the drop test.
Benefits to the customer include:
Cost savings – the new corrugated solution is much more cost effective now that the foam element has been removed. The old pack cost was £22.00 and the new pack cost is £9.90, which totals circa £60k worth of savings over 5,000 units/annum. Furthermore, plastic tax charges have been removed from their business operations.
Packaging efficiencies – the new pack is much easier to fill with product The fittings are designed to fit into the outer pack and stay into position. This allows the product to packed easily without the inner packaging moving about.
Sustainability – There is no longer any need for foam as the new solution is manufactured from 100% corrugated board that contains at least 70% recycled material. The pack is fully recyclable by the end user.
Customer feedback has been entirely positive and during the process they were amazed at how corrugated, and our team, could create such a solution and succeed where others had not.