Custom Product Packaging Folding Box Case Study

Product Packaging Challenge #103: After-market Automobile Headlamp Product Package

Problem: Complex product packaging processes too costly and inefficient
A customer approached Crown Paper Box looking for a solution to a product packaging concept dilemma. The customer was using a paperboard carton to package after-market automobile head lamps. The folding cartons included all the graphics needed for the selected channel and did a good job of protecting their relatively fragile glass product through distribution. The problem was that in order to protect the lamps, the product packaging, cartons of various size, were unusually complex, difficult to manufacture, and more expensive than the customer felt was necessary. The customer also felt that a different and better folding carton would improve the efficiency of the packaging department, cause fewer stoppages in the packaging machinery, and reduce breakage of the product.

That was a tall order and challenged Crown's decades of knowledge in box design and in packaging line operations. In partnership with the customer, Crown Paper Box set out to find a solution that met all the customer's package requirements for efficiency, product protection and machine ability through the line - all without decreasing the shelf appeal of the graphics which the customer felt were providing an advantage of its much larger multi-national competitor.

Solution: New concept using F-Flute corrugated Foldcorr™
The solution was an entirely new creative solution in which the folding carton was constructed from F-Flute corrugated, marketed by Crown Paper Box under the FoldCorr™ trademark. Crown had developed a printing process that allowed it to print offset lithography graphics on sheets of F-Flute corrugated paperboard. Crown had solved the problems of maintaining register and color density on this medium felt by others to be too unstable to print on directly. Crown's process eliminated the expensive step of either applying labels to a finished box or laminating registered top sheets to corrugated single face. It produced a finished printed sheet of FoldCorr™ ready to be die cut, folded and glued to the customer's specifications.

Result: Increased through put; Reduced net package cost and spoilage
The customer was delighted with the new ready-for-retail packaging. Crown's new-to-the-world design had the graphic appeal of its paperboard predecessor. It was a more simple construction, and provided even better product protection than its predecessor package. The packaging line, tuned with the assistance of one of Crown's experts, allowed the packaging line to take full advantage of the new folding carton, and the customer realized significant gains in through put, net package cost, and spoilage.

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