Achieving a 367% sales increase and 65% cut in damages

This UK mirror manufacturer ships a huge variety of high quality mirrors to retailers and end users across the UK and EU, using a ‘white gloves’ delivery service. When they began selling through a large homeware e-commerce channel, they needed a ‘bomb-proof’ transit packaging solution to protect fragile items despatched through the retailer’s usual carrier network.

The Problem

The manufacturer was distributing endless shapes and sizes of mirrors, and seeing transit damage rates of over 18%. These damages meant they were receiving complaints from customers and spending huge amounts of time and money on managing returned items. Space was a major issue for them so they needed a packaging solution that could be assembled quickly in small spaces whilst keeping storage to a minimum.

Our Solution

We visited the company’s factory to assess the situation, looked at what they were shipping, their method of transport, and how they were packing them ready for despatch. Their combination of bubble wrap, cardboard boxes and blue U-Profile foam corners to package their mirrors was not delivering the protection needed so we recommended a solution to eliminate internal movement completely, once packaged.

Nuevopak™ X-Pad™ void fill is recycled, and recyclable, paper padding which we placed directly around the mirrors to prevent them from moving in transit. We also created an overpacking solution to be placed over the inner cardboard carton containing the mirrors. Using self-adhesive recyclable foam corners and foam edge protectors, we created a buffer zone to absorb the impact of any knocks or bumps. After testing proved this to be the optimal solution, we gave the warehouse operatives extensive training in how to use it.

Project Outcomes

  • Damage rates reduced by 65%
  • E- retailer rewarded the cut in damages with extra promotion, leading to a huge 367% increase in sales
  • Fewer returns and customer complaints
  • Enhanced brand reputation

  • Less time and money spent dealing with returns
  • Increased storage space as box range standardised
  • Lower environmental impact with recycled recyclable void-fill solution
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Personal Approach

Listening to the needs of each client and responding with smart solutions

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Leading edge technologies

We use a global network of partners to bring you the latest packaging innovations at competitive prices

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Our Team

Our team of experts includes technical consultants, packaging technologists, project managers and procurement specialists. Many of them have been with Hazel 4D for over 20 years.

To see their smiling faces, visit our meet the team page or get in touch to arrange a site visit.

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Case Studies