CLIENT RESULTS
Packaging solutions that solve real problems and save real money
From foam redesigns to refurbishment programs, see how we've helped manufacturers, contractors, and distributors cut costs without cutting corners.
14%
cost reduction per crate
42%
saved vs buying new
10+
industries served
How We Saved a Speaker Manufacturer 14% Per Crate Without Compromising Protection
A well-established speaker manufacturer came to us with a complex packaging challenge. With over 10 unique crate designs in rotation and weekly orders going out the door, their foam-lined crates were a critical part of keeping their products safe in transit — but the cost of that protection was adding up.
The Challenge - Because each crate had been designed independently over time, the foam inserts across their product line were all slightly different shapes and sizes. That meant more material variety, more waste, and higher costs baked into every single order. They weren't overpaying on purpose — it had just never been looked at as a whole.
What We Did - We took a step back and audited all 10+ crate designs together. Rather than treating each one as a separate problem, we looked for opportunities to standardize foam shapes across the entire product line — using uniform cuts that could protect multiple speaker models without any compromise to fit or safety.
It was a straightforward idea, but it required understanding both the geometry of each crate and the protection requirements of each product. Once we mapped it out, the savings were clear.
The Results - On one crate alone, the redesign brought the cost down from $431 to $371 — a savings of $60 per crate, or roughly 14% reduction in cost. Multiplied across their weekly order volume and full range of crate designs, those savings compound quickly.
Their products are just as protected as before. The only thing that changed was the bill.
What This Means for You - If you're ordering custom foam packaging across multiple product lines, there's a good chance you're leaving money on the table. A fresh set of eyes on your full packaging lineup can often find savings you didn't know were there.
How a Foam Refurbishment Program Saves an Aerostructures Company 42% Over Buying New
In the aerostructures industry, the components being handled aren't just expensive — they're precise. Protecting them in transit isn't optional, and the foam-lined boxes that cradle those parts need to be in good condition every single time they're used. For one aerostructures company, that standard was creating a recurring cost they hadn't found a better answer to — until we built one together.
The Challenge - Their foam-lined boxes were getting heavy use. Parts going out, parts coming back, cycle after cycle. Eventually the foam would break down to the point where it could no longer do its job. The obvious solution was to buy new boxes — but with two part types in rotation and orders of 30 to 80 pieces returning twice a month, replacement costs were a constant drain.
What We Did - We set up a foam refurbishment program specifically for their operation. Rather than replacing the entire box when the foam wore out, they now ship the boxes back to us twice a month. We pull out the old foam, replace it with fresh inserts cut to the same spec, and send them back — ready for another full cycle of use.
The boxes themselves keep going. Only the foam changes.
The Results - The numbers speak for themselves. Buying 100 replacement units outright costs $35.02. Getting 100 foam inserts refurbished through our program costs $20.34 — a savings of $14.68 per 100 pieces, or roughly 42% less than buying new.
With 30 to 80 pieces returning twice a month across two part types, those savings add up to a meaningful reduction in packaging costs over the course of a year — without any change to how their operation runs or the level of protection their parts receive.
What This Means for You - If your team is regularly replacing foam-lined packaging because the foam wears out, you may not need to buy new every time. A refurbishment program can extend the life of your existing boxes significantly — and cut your per-cycle cost in a way that compounds over time.
How We Helped a Government Contractor Stop Overpaying on Every Order
For government contractors, cost efficiency isn't just good business, it's often a requirement. Every dollar spent on materials and components needs to be justified, and recurring inefficiencies in a procurement process can quietly eat into margins order after order. When one contractor came to us needing a custom foam component, we saw an opportunity to structure the relationship in a way that would save them money from day one.
The Challenge - The contractor needed to purchase a custom part from us on an ongoing basis. The problem with ordering one-off or in small quantities is that every order carries its own setup fees and labor costs. Expenses that get baked into the unit price each time. For a customer with consistent, predictable demand, that model just doesn't make sense. They were effectively paying a premium every single time they reordered.
What We Did - We proposed a build-up plan. Rather than producing small batches on demand, we worked with the contractor to determine the optimal production quantity — the run size that brings the per-unit cost down to its lowest point by spreading setup and labor costs across a larger batch. We then produce that quantity, store the inventory in our warehouse, and the contractor pulls from that stock as they need it, in whatever quantities work for them.
They get the flexibility of ordering small amounts on their own schedule. They pay the storage fee. And they never pay inflated per-unit costs again.
The Results - By shifting from reactive one-off ordering to a planned inventory model, the contractor now gets the same parts at a meaningfully lower per-unit cost — without needing to carry the inventory themselves or change how they place orders day to day. The savings are built into every single pull from inventory, for as long as the program runs.
What This Means for You - If you're ordering custom components in small quantities on a regular basis, setup and labor fees may be quietly inflating what you pay per unit. A build-up and storage program can eliminate that overhead — we handle the production planning and warehousing, and you get better pricing with the same flexibility.