Converting Case Study


How a business card box designed by Antalis is helping Commercial Foundation to reach its goal of no plastic

usiness cards are just one of the digital and wide format print and promotional merchandise offerings

from WE DO. Print whose workers are young people attending the #NoLimits course run by Commercial Foundation. This social enterprise was established in 2015 and supports disadvantaged young people to develop practical skills to help them find a job or future career. Commercial Foundation were packing

their orders for business cards into standard 70 mm-high plastic business card boxes which were then packed in a bubble-lined mailing bag for posting. As well as not being very environmentally friendly, the packages were also too big to fit through letterboxes. A drive to reduce its use of plastics

prompted the Commercial Foundation to seek a more user- and environmentally friendly alternative. After taking the time to understand the complete process around WE DO. Print’s business card service, Antalis Smart Packaging Centre came up with workable solution.

Using the information provided, Antalis’s

packaging technologists put forward three options: a box and lid design and two variations based on the 0427 pizza box

box is now in use and is bringing numerous benefits to both Commercial Foundation and its customers: •

Customer experience - more

convenient and easier to recycle – aligning with public demand for more environmentally friendly products – the cardboard box also offers a handy place to store the business cards. •

certified board, the new box design has eliminated use of plastic and secondary packaging materials. It can also be recycled easily. •

structure. The team also advised on the possibilities of printing the box to enhance the customer experience. Commercial Foundation’s preferred

design of the three was an 0427 style box with four compartments, made from FSC- certified board. It allows the customer address to be affixed to one side of the box and space for a message from Commercial Foundation along with environmental information is printed on the other sides. The new box was put through its paces to assess ease of assembly, durability, and postability. Following the successful trial, the

Environmental – Made from FSC-

Cost saving – the new box design

is slightly more expensive than the plastic box being used originally, however the elimination of the secondary packaging has resulted in an overall cost reduction. Ian Whitcombe, National Key Account

Manager for Antalis Packaging, commented: “The whole project, from the initial consultation to roll-out took just six weeks. It’s a great example of how taking the time to really listen to our customers’ needs, challenges and frustrations can result in


really innovative box design that achieves far more than the original goal.”

Kewell Converters adapts to provide PPE K

ewell Converters Ltd (KCL), a family- owned British manufacturer of speciality foam products, responded

to the COVID-19 pandemic by producing over 6 million foam visor pads for essential personal protective equipment (PPE) to date. Within a week of the UK’s lockdown in

March, the company was receiving a large volume of enquiries from companies needing components for the production of reusable clear plastic face visors. As a specialist in closed-cell foam manufacture, KCL was uniquely positioned to advise and produce one key aspect: the foam part of the headband, which separates clear plastic sheeting from the face and makes the visor comfortable to wear for extended periods. “Our clients needed advice on densities,

hardness and even colour,” explains Malcolm Newington, business development manager. “We were able to provide samples and prototypes quickly and get the visor pads into production without delay in order

26 October 2020

its clients. Colin’s sons Nick and Marcos are now Directors of the business. “We have had to adapt quickly to new

for our clients to start manufacturing PPE. We put prototypes on client’s desks as quickly as 48 hours from initial enquiry.” Founded in 1971, KCL has grown from a single homemade machine in the late Colin Kewell’s garage to a thriving, industry- leading enterprise that counts Aardman Animations, Elekta and Grundfos amongst

ways of working, not just because of the unexpected global demand for PPE but to ensure our staff are safe while they’re on the factory floor,” states Marcos Kewell, commercial director. “We introduced a new two-shift pattern of working and upgraded our hygiene practices to make sure everyone is protected.” The demand for PPE components has accelerated KCL’s investment in new plant and machinery. KCL has supplied UK-based companies such as Mauveworx and Protecting Heroes with foam visor pads. Demand for PPE is now very strong and KCL has also seen indications that the manufacturing industry as a whole is starting to return to business, with new enquiries coming in from outside the medical equipment sector.

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