StampSource

Clamshell Packaging for a Decking Hardware Kit

Decking Hardware Kits

With our talent for problem-solving, StampSource engineered a smart packaging solution for composite decking hardware kits to attract retail sales and deter theft.

Problem:
This decking hardware kit was previously packaged in a polybag for retail point-of-sale purchase. The packaging did not maximize sales and had unacceptable loss rates due to theft.

Solution:
As a full-service company equipped to manage the design, manufacturing, kitting and fulfillment, we had the perfect background for helping this customer find a solution. We collaborated with the client to develop a clamshell package that incorporated features that improved consumer impact while also housing an unobtrusive security tag. This robust package aligns with the retail footprint, protects the contents and provides ample space for the client to convey their marketing message.

This clamshell kit measures 7” x 5” and contains an assortment of powder coated brackets, screws and other hardware that we manufacture. In addition to the security tag, we assemble the kits with marketing header cards, labels and barcodes and then package them in display boxes. We developed a work cell based on the one-piece flow concept to ensure a high level of quality while allowing for scalability, flexibility and minimal inventory overhead. This production model allowed us to maintain the unit cost structure and we implemented a timetable that ensured an uninterrupted supply of product.

Results:
Transitioning to our totally new packaging concept, with its more appealing design and built-in security feature, was the ticket for success. Along with an immediate upsurge in sales, loss from theft dramatically decreased. We now produce upwards of 125,000 kits on an annual basis.

If you are interested in learning more about this project or our end-to-end contract manufacturing capabilities, contact us directly.

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Clamshell Packaging for a Decking Hardware Kit Project Highlights

Capabilities Applied/Processes
Packaging and Marketing Solutions
Kitting
Sonic Welding
Assembly
Progressive Stamping
Progressive Die Building
Powder Coating
Fulfillment
Staking
Hinge Production
1 Piece Flow Assembly
Kanban/Pull
Equipment Used to Manufacture Part
200 ton Press
110 ton Press
80 ton Press
Progressive Feedlines
60 Ton Assembly Press
Sonic Welder
Overall Part Dimensions
Clamshell Kit 7" x 5"; Brackets 2" x 2"; Screws 1" and 2"
Tightest Tolerances
±.002"
Material Used
304 SS Coil, 304 SS Hinge Pins, 18-8 SS Screws, Plastic Clamshell Containers, Security Tag, Driver Bit, Marketing Header Cards, Display Boxes, Display Labels, Barcodes
Material Finish
Powder Coat
Industry for Use
Composite Decking
Volume
125,000 Kits +
Delivery/Turnaround Time
Vendor Managed Inventory, Daily
Delivery Location
Central North Carolina
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