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.

The process

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

• 1. Explore: Time was spent with with the bike packing distribution team asking them questions. 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 easier to manoeuvre; and a separate insert to keep the bikes secure within the box. 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 box that would accommodate the wide range of bicycles sold. The use of a separate insert would ensure bicycles of different sizes would remain secure in the box and overlapping flaps and hand-holes were added to the boxes' design. Finally, Antalis recommended the use of Filipak TT, that 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.