Case Studies:

Case Study #1 - One’s problems can be another’s challenge for success

Custom Pack was contacted by a prospective client with the task of creating a successful UPS shipping concept.  Part of their product line consisted of heavy insulated glass doors and side panel window inserts.  These window panels were comprised of leaded insulated glass fixed to an injection molded outer frame.  The glass units exceeded $600 in cost and could only be successfully shipped via common carrier.  Common carrier charges well exceeded that of shipping via UPS or Fed Ex.  The current packaging consisted of a 40” x 48” pallet, four molded EPS corner protectors, two molded EPS side protectors and a 275# double-wall carton.  The final assembly consisted of loading the glass panel cartons on their edge and pallet strapping it into position on the pallet.  This caused excessive shipping charges in that it was impossible to pack anything on top and the cost to ship that assembly was over $100.

After careful review of the circumstances, Custom Pack looked at the possibilities of incorporating cushions of Polyethylene Foam on all four corners to absorb direct shock from a 90˚ corner hit.  The thickness of the Polyethylene accomplished that task successfully.  Also, either two or four side-panel inserts of Polyethylene Foam were incorporated into the design concept to better distribute the shock.  During UPS testing, the packaging still needed to be tweaked a bit.  It appeared that a very small stress crack appeared in the glass.  That problem was easily solved with the addition of two inflatable polyethylene dunnage pillows positioned on either side of the glass panels between the panel and the outer corrugated wall.

Today, all the panels that at one time were shipped via common carrier can now be shipped successfully by UPS as tested in a UPS-certified lab.  The end result was more than a 65% reduction in their shipping costs.

Case Study #2 - Successful marketing techniques can create a lasting impression

During difficult economies, many companies will see cutbacks in advertising dollars.    Most companies do not realize the importance, nor do they have the resources, to kick up advertising during down times in an effort to jumpstart their business.  Typically, advertising is one of the first budget items to get slashed, and dollars left to use in that category after reductions have to be used on a marketing tool that will have a dynamic impact.

Custom Pack had the privilege of being contacted by a prospective client who realizes the importance of “getting the biggest bang for your advertising buck.”  The company had reserved advertising dollars for a campaign that they knew could reach at least 10,000 prime locations if marketed and distributed in the proper manner.  And thus began the packaging challenge for our design team………....

The client’s specifics were that we needed to create a distribution bag for use at the Pharmacy level to accommodate insulin, syringes, and an information magazine.  We were told that the insulin must remain cold in the bag for at least two hours, and that it must be strong enough to support a magazine weighing about 8.1 ounces.  However, they had to be contained in their own compartments to prevent contamination.  The magazines would be inserted into the bags, packed as many as possible into cartons weighing no more than about 30 lbs., and shipped to 10,000 pharmacy locations.  Prior to consumer dispensing, the insulin and syringes would be inserted by the Pharmacy into the bag.  The customer would then obtain their medication along with marketing literature.

After careful consideration of all the requirements, we devised what we call a “Promotional Divider Bag”, which can be viewed below and in the images of Custom Pack’s Flexible Packaging section on our website, www.custompackinc.com.  Not only would this bag accommodate the insulin temperature requirements and syringes with its rear metalized, leak-proof, zipper-closure section, but it would also allow the magazine to show clearly through the separate clear front kangaroo pocket - an ideal solution to a two-fold problem.

For this project and many others that we pursue, not only are we able to devise a package that will accommodate the customer’s needs, but we are also able to fulfill the assembly requirements of the package, as well as packing the cartons, warehousing the product, and making on-time shipments to all the Pharmacy locations.  That is what we call one-stop shopping convenience.

Flexible Packaging, Thermoforming, Foam Fabrication, Folding Cartons - Custom Pack Inc.
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