How to improve packaging for large home delivery

The client's challenge

With lockdown forcing the closure of brick and mortar stores and the demand for bicycles soaring, the retailer quickly developed an e-commerce store so they could continue selling goods and meet the rising demand. Packaging the bicycles, however, proved more problematic.

They needed packaging that both fitted a variety of bicycle sizes and was easy to assemble and handle - something their then current packaging supplier couldn’t offer. After looking for alternative suppliers online, the owner of the shop came across Antalis and contacted them to see if they could help.

The Antalis solution

Bespoke box design in three different sizes to accommodate small, medium and large sized bicycles. The boxes are made from a 200gsm corrugated board in a BC flute with a kraft paper outer and inner (200K/BC/K). A cardboard insert fits around the bike, keeping it secure, while Filipak TT paper void fill adds extra protection during transit.

"As a new entrant to web/home delivery sales we have been very pleased with the service received from Antalis. With rapidly changing sales and a big need for packaging to fulfill those orders, Antalis has proven itself to be an extremely dependable supplier, capable of both managing our packaging availability and controlling our costs."

Our client.

The process

Using a clear framework, the Antalis packaging team set to work developing a solution:
 

• 1. Explore: Antalis visited the clients' site to gain a clear understanding of the requirement. Time was spent with the team who pack the bikes ready for distribution, asking them questions about what they felt would make it easier to pack the bikes. Among the requested packaging features were overlapping box flaps to add extra strength to the top and bottom of the boxes; hand-holes so the boxes would be east to maneuver, and a separate insert to keep the bikes secure within the box. Atalis learned that the client also wanted their boxes to be custom printed with their brand, something the previous supplier hadn't been able to offer.

• 2. Propose: Antalis proposed three sizes of bicycles sold. The use of a separate insert would ensure bicycles of different sizes would remain secure in the box. To meet the requirements of the packers, Antalis recommended the use of Fillpak TT. which converts sheets of kraft paper into environmentally-friendly void fill. to protect the bicycles during transit.

   

• 3. Test: Antalis produced a sample box that met every requirement on the dream list. Delighted with the sample, the client placed an order, no testing required.
              
• 4. Implement: Initially, Antalis delivered 100 of each kind of box every week, and as the client’s business has expanded Antalis has been able to continue supporting their growth.