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Description
Karton Pak is a family business that deals with production, processing and shaping of all types of commercial packaging made of corrugated cardboard with the possibility of multi-color printing. It has over 450 regular customers and they are constantly growing.
At this point, Company’s capacity to satisfy the growing demand is limited, due to outdated machines. The machines are slow, they use a lot of energy, and are not environmentally friendly. In addition many features are manual, meaning it takes a lot of time for a unit of product to be produced. Furthermore, their ability to generate creative new solutions in packaging (regarding colors, creative samples) is limited.
Currently, creative limitations of the existing machines are being resolved through outsourcing – when the customer wants specific creative packaging solution, Karton Pak outsources creation of a sample to another company. This is not optimal, since in reality, only 1/3 of created samples that were outsourced is accepted by the client, while Karton Pak has to pay for the service anyhow. Outsourcing is costly, it also adds time to service delivery.
Because of outdated technology, Karton Pak is not able to satisfy the growing demand on the market, it offers longer than optimal delivery terms, the quality is lower and prices of its products are higher. This means that eventually, Karton Pak will lose its customers if it fails to invest into new equipment that will increase its productivity and enable production of more creative carboard packaging solutions.
With this project, Karton Pak is investing into the following machines:
- for cutting the sheath of cardboard packaging
- for drawing/shaping
Since the investment will increase the capacity, provide for more flexibility with shortened delivery terms, with decrease of overall costs, Karton Pak will be more competitive, and as a result will increase its revenues and profit
Summary of project results
This project addressed the company''s inability to meet growing demand, due to Karton Pak’s outdated production processes. The outdated production processes resulted in limited capacity and delayed deliveries, risking customer loss to competitors. The project also aimed to reduce reliance on external services for sample and mould creation, while adapting to increasing market complexity and competition.
To address these challenges, Karton Pak engaged in the
- Procurement of Advanced Machinery: The company acquired two state-of-the-art machines – one for fully automated, high-efficiency production, and a 2D printer for rapid prototyping and small batch production, enabling faster and more complex product development.
- Internal Sample and Mould Production: Using new equipment, the company is now able to produce samples and moulds in-house, which reduced its reliance on external suppliers. It also shortened production times, and improved flexibility in meeting customer demands.
After implementation of this project, the company has significantly improved production efficiency and reduced environmental impact. Customers are benefiting from faster delivery times, more complex packaging solutions, and greater product customization. While Karton Pak has strengthened its market position, reduced operational costs, and improved compliance with sustainability standards, its employees gained new skills and work with greener, advanced technology.