The problem. The engineering. The result.
Lower shipping volume. Faster assembly. A cleaner retail launch. Explore the decisions, samples, and measurable results behind eight customer projects.
Browse by buyer type, then open the complete project.
OEM / KD structural redesign
A North American retailer was paying to ship the empty space inside a semi-assembled cat house. We rebuilt it as a KD flat pack: 2,960 sets per 40HQ instead of 1,850, with downstream damage reduced to 0.28%.
Large North American retail channel operator
See the engineering & resultsOEM / board and export-pack engineering
A German distributor needed scratchers that stayed rigid through sea freight and warehouse stacking. We changed the core and protective pack together, lifting measured strength by 45% and stacking from three layers to five.
Leading German B2B importer and distributor
See the engineering & resultsOEM / tool-free assembly and parcel pack
A US e-commerce cat house was expensive to mail and frustrating to build. We replaced the assembly with tool-free locking joints and rebuilt the mailer around the product, cutting weight by 14% and carton damage to 0.4%.
Leading US e-commerce and direct-to-consumer brand
See the engineering & resultsOEM / seasonal print and PDQ-SRP packing
A delayed supplier had put a UK supermarket's Black Friday range at risk. We delivered the seasonal order six days ahead of plan and combined transport protection with PDQ display, cutting shelf setup time by 65%.
Established UK supermarket chain private-label program
See the engineering & resultsODM / nesting and replaceable-core development
An Australian retailer needed its lounge and refill range to earn more from the space it shipped. We nested two replacement sets inside the lounge, kept the outer carton unchanged, and increased ex-factory goods value per carton by 42%.
Large Australian pet and home retail channel
See the engineering & resultsOEM / precision finish and packing control
A premium Japanese retailer could not accept rough cut edges, unwanted odor or exposed glue. We connected precision die-cutting and plant-starch adhesive with individual protection and pallet-aligned cartons, keeping batch appearance and structure defects at ≤0.08%.
Japanese premium department-store and retail-chain buyer
See the engineering & resultsCatalog assortment / modular export packing
A Canadian wholesaler needed a mixed cat-product load without cartons crushing one another. We coordinated six SKUs around two outer-carton modules, improved container utilization by 17 percentage points, and reduced packaging cost by 23%.
Leading regional Canadian pet-products wholesaler
See the engineering & resultsODM / cross-slot structural engineering
Two previous factories had treated strength and flat packing as competing requirements. We replaced complex glued construction with internal cross-slot joints, increased the project’s static-load result from 12 kg to 35 kg, and raised loading to 2.4× its previous level.
Premium retail-chain program serving France and Central Europe
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