We can always find a solution
Since 1860 we have been providing cardboard solutions for a huge variety of businesses and applications.
The majority of our work is laminating bespoke boards which means sticking different layers together to make completely unique products for our many clients’ complex requirements.
From there, we can convert further. We can die cut, we can glue for applications like envelopes, we can mould to make nested trays for food packaging, we can guillotine to any size, we can bundle to any requirement. If it’s made of cardboard, we have the specialist setup to create EXACTLY what you want.
Case Studies
These case studies are great examples to demonstrate our core strength. We listen to our clients and know the questions to ask. Then, using the unrivalled experience of the team, we are able to develop custom solutions at a price that works.
New Packaging for Soap
The customer exports soap, and had a problem with grease ingression on the sheets dividing the layers of soap bars within a transit pack. The grease was causing the soap to stick to the layer pad, and they wanted a white board that would prevent the soap from sticking and then breaking when being removed from the pack.
Solution
We came up with a completely new product, which was much thinner than we had made previously, but that had the anti-stick properties desired on both sides and which still fulfilled the requirement of the white colour. Following successful trials, this board has remained unchanged for many years.
Cardboard handles
The customer was using plastic handles stitched into their paper potato sacks for the retail sector. They wanted a recyclable alternative, which was strong enough to carry the weight of multiple kilograms of potatoes, but would still be appropriate for their existing production processes. The handle was very thin at the join with the sack, presenting a weak point, so it needed to be designed so as not to tear or break.
Solution
We trialled many combinations of papers and boards to find one that would be strong enough to withstand the weight requirements of the sacks, and eventually engineered one, using the strongest materials available which had sufficient strength not to tear.
Product protection
The customer was using cranes to lift valuable product reels. They were using double sided tape to stick plastic sheets the outside of the reels, in order to protect them from being damaged. This was a very time-consuming process.
Solution
We designed a board diecut shape, which was made using a self-adhesive liner to eliminate the need for double sided tape. We ensured that it was made thick enough to absorb any scrape damage and leave the product unblemished.
Pallet sheets
The customer manufactures powdered chemicals and distributes them packed in large bags on pallets. The bags being exported were suffering serious damage in transit when the pallets could move inside the container and the double stacking of pallets compacted the bags, damaging them further.
Solution
We designed a thick rigid cardboard pallet sheet to place in-between pallets to help distribute the weight, and prevent pallets on top rubbing against bags beneath. It also aided in preventing product compression.
Patisserie Packaging
The customer had a specific design and specification in mind for their high-end patisserie boards but were unable to find the correct product off-the-shelf. The time frame was very tight as they were wanting to coincide with the launch of their new patisserie department.
Solution
We were recommended to them by another supplier, and we were able at short notice to design a board which suited all their requirements. We produced a small trial run, and machine-made samples in order for the customer to assess how the actual product would look and feel, and then we turned a full order around in time for the launch day.
Bespoke fruit punnets
We make cardboard fruit punnets with cardboard lock-in handles. When we first rolled out the handles, our customers liked them, but they were susceptible to moisture ingression and subsequently tearing.
Solution
We designed a new handle material, which used a much stronger, water-resistant board. The diecut handles were easier to insert into the punnets, and the conclusion was a better all round user experience whilst solving the initial problem.
Product protection
A customer printing childrens’ paintings and sending them out through the post, was using heavy MDF backing board. This increased the postage costs significantly.
Solution
We designed a board alternative which looked nicer, and gave a similar rigidity to the MDF, whilst weighing considerably less. We subsequently rolled this option out to our other picture framing customers, and it became an industry standard product used by many in the industry.
Value Added Products
Expert customer support
Tell us what you need, and our expert team will work with you to find the perfect solution. If it's made of cardboard then we are the people to speak to!
Get in touch today to see how we can help.