Styropack Solves Sink Supplier's Packaging Problems

Leading kitchen sinks and accessories manufacturer, Astracast is expanding into an exciting new wholesale market in the US. However, it found that its transit packaging did not deliver the goods.

Natasha McCreesh, Purchasing Manager, Astracast, explains: "We had been sending our sinks packed and palletised to the DIY sector in the US - the packaging system we had was totally appropriate for this delivery method.

"Then we began supplying to wholesalers; we had operators delivering individual sinks straight to customers' homes. With this new distribution method, we had between 30 and 40 per cent of our products returned because they arrived damaged. This gave us a huge logistics problem and - it was stifling growth in a new sector.

"The packaging is a vital part of our product, we had to make sure we got it right. We examined four options: modifying our existing system, corrugated cardboard, moulded EPS (expanded polystyrene) and moulded pulp.

"Our key criteria were the protection performance, cost, the environmental impact, packing time and quality control. We had samples made of each system and put them all through rigorous transit testing. We even drove them around the UK in a van!"

Of the options, moulded EPS supplied by Styropack was not the cheapest option, but for Astracast it was definitely the best, says McCreesh: "Styropack took a totally proactive approach throughout our discussions.

"We had a problem with storage and they offered to set up a very flexible JIT delivery system for us. They gave us advice and information about using flame retardant material and about recycling.

"The other great benefit of using EPS is the time saved in packing the sinks and quality control is no longer an issue - with EPS we know it will be correct every time.

"Styropack ensured that we had a really smooth transition to the new packaging. The team resourced it well and ensured that they spoke to the right people to iron out any issues and to make the whole process completely painless for us. We are just about to launch the big volumes and I am confident that Styropack will manage it perfectly for us."

Astracast are so pleased with the US packaging they are changing all their UK and Europe sinks over to EPS packaging too; "We have given Styropack the challenge of designing packaging for 54 sinks using 10 tools," says McCreesh. "I am sure they'll do it!"

For Styropack working with an organisation like Astracast has been enjoyable and challenging: "Astracast is a top quality manufacturer and it is a pleasure to do business with such an efficient organisation," says Paul McCoy, Business Manager.

"It is very satisfying for us to take on a customer and to help them solve a problem as we did in this case. Astracast was very receptive to our ideas, working with the team there was a real meeting of minds."

The total value of the Astracast account is worth over £800,000 to Styropack.