|Case study demonstrating how
intelligent design, combined with pack engineering and
vision can dramatically increase sales.
Our client Staples Disposables is one of the UK's largest
independent manufacturers of disposable cleaning and hygiene
Their philosophy is simple
“While quality and value for money are always of
vital importance, the design of the tissue pack is often
the most critical factor in the purchasing process”.
Consuma products are successful largely because of their
strong emphasis on design which is complimented by a strong
in-house design team and strong links with excellent external
One of their retail customers Marks and Spencer were looking
for an oval shaped pack made entirely from card, so Staples
turned to Concept as one of their external agencies because
of their vast experience in engineering packaging with
shape and curves.
We developed an oval carton with a quick erect crash style base.
We then created a dual layer oval card lid from thick double
wall corrugate latex mounted to a decorative printed card. The
lid was connected to the carton via a neatly designed tucking
In addition Concept provided the assembly methodology and tooling
to enable Staples to erect and pack the cartons quickly and
easily to complete the process.
||Having created the process Concept
then continu ed to monitor, develop and re-engineer different
aspects of the pack to continually improve speeds and
In order to meet increasing volumes and engineer further
cost out of the process Concept encouraged Staples to
move to an injection moulded lid. We designed a lid which
clipped into specially designed features on the inner
carton wall which was profiled to glide in quickly, making
assembly of the new packs much faster and easier.
Concept had also developed a new simpler stronger base
for the oval carton and this was incorporated into the
new packs for Morrisons and Tesco.
By working closely together with Staples, Concept have
created a unique shaped pack which has met its key objectives
of appealing to the consumer as well as the client.
In fact its appealed so much to the consumer that’s
sales have grown from a one off order for 25,000 units
to approaching 1 million packs per annum.
The next stage is automation and again Concept are working with
staples to provide the solution. Concept has previous experience
of automating various shaped cartons and have identified a machine
system suitable for erecting the Staples Oval.
A new lid has been designed to further lower unit costs.
Chris Hallam Concept Packaging MD commented “When
our customers are ready to move forward we are usually already
involved in the next stage of development so can react quickly
with much of the work already done. The dramatic growth of sales
is testimony to a well-designed pack meeting all the clients