The Box That Finally Survived the Ride (E-comm SIOC)
Cluster/Port: Bhiwandi → Nhava Sheva
A home & lifestyle brand kept getting dinged by marketplaces for transit damage. Photos showed crushed corners and split seams; returns were noisy and expensive.
We paired the buyer with a solid corrugation partner in Bhiwandi, set a two-week sprint, and kept everyone on a tight calendar: new carton sample, quick test, pilot, roll-out. The converter did the engineering; we kept the plan moving and booked an independent ISTA drop/compression test so the buyer trusted the result. On the packing line, we added a simple visual checklist so the “right” inserts and tape pattern were used every time.
What changed:
- Damage rate 4.8% → 0.6% (penalties disappeared)
- Carton/insert redesign cut wasted space; freight per CBM ~7% lower
- Line setup time ~22% faster thanks to a clear kitting SOP
Our role: shortlist supplier, run the sprint, book ISTA + pre-shipment QC, deliver photo-rich evidence.
Factory role: redesign carton/insert and produce.
The Pouch That Kept the Crunch (Barrier Upgrade)
Cluster/Port: Ahmedabad/Surat → Mundra
A food brand loved their new snack, hated the stales. Shelf-life targets weren’t holding; a few warm-weather lanes were the worst.
We introduced a flexible-pack specialist in Ahmedabad/Surat and agreed on a simple plan: two laminate options, quick bench tests, then a lab run for barrier numbers. The converter proposed a smarter layer stack; we handled the sample calendar, lab booking for oxygen and moisture transmission, and a small store-shelf trial before the full PO.
What changed:
- Oxygen ingress down ~60%, moisture down ~55% (fresher product)
- No visible cost blow-up (≈ +1% offset by better yield and fewer rejects)
- Launch stayed on schedule; fewer freshness complaints
Our role: match the right converter, schedule samples/lab tests, keep paperwork and dates tidy.
Factory role: make the laminate, dial in sealing, deliver the pilot.
Labels Without the Liner (Linerless, Less Waste)
Cluster/Port: Noida/NCR → Nhava Sheva
The brand’s ops team was tired of hauling away mountains of release liner. Material waste felt wrong—and expensive.
We lined up a label converter in Noida and an applicator OEM for a joint trial. The converter brought linerless rolls; the OEM adjusted the applicator head; we coordinated two plant trials and kept the buyer’s team in the loop with short videos and numbers.
What changed:
- Material usage ~35% lower (no release liner)
- CO₂ footprint ~20% lower (less material + waste)
- Line speed +10–15% after the second trial; fewer roll changes
- Total applied cost landed neutral to slightly better vs. old setup
Our role: find the right pair (converter + applicator), run trials, track results, and button up specs.
Factory role: produce the labels; OEM tune the applicator.
