(an eye for detail, a nose for business & always an ear to listen)
Strategically situated in the heart of the UK and operating from four large manufacturing and storage facilities, The Box Factory is continuously developing creative packaging solutions and cost saving initiatives in partnership with our customers. To do this we utilise the experience of our in house design centre and many years of manufacturing expertise.
Whatever your packaging requirements, we are able to provide cost effective, tailor made solutions.
CREATIVE DESIGNS ALL MADE TO MEASURE
Our in house design department operates the latest industry standard software package, AG Kasemake 2000. This is complemented by a fully computerised cutting/plotting table capable of producing one piece samples up to 1580 x 3000mm in size.
To ensure complete continuity from the initial sampling stage through to full scale production, our design software is linked via the Internet to our cutting forme and printing stereo maker's software, thus minimising any translation problems that may occur during tooling production.
With fully trained in house designers we pride ourselves on design flair and our open-minded approach when developing packaging solutions.
We can offer you an almost infinite range of regular cases, all manufactured to your exact size and grade specification, using our state of the art converting equipment. No tooling is generally required for these types of boxes and as our machinery is capable of producing 15,000 units per hour, no order is too big. These boxes can be flexographic printed with up to 4 colours, all in one process.
Generally a variation of our standard boxes, Shelf Ready Packaging (SRP) has become increasingly popular, especially within the food processing industry. A huge variety of these packs can be seen in most supermarkets and all are tailored to specific requirements, usually product size, quantity per pack and the designated shelf space within the store. This style of box will require some type of cutting tool (forme) that enables us to add cut-out sections and perforations to the finished product.
The world really is your oyster with this type of box and the only limitation is imagination and creativity. These boxes require a cutting forme which enables very intricate and precise designs to be realised. High volumes are effortlessly achieved and once again these boxes can be printed as specified.
A huge variety of fittings can be designed to protect and support almost any product during transit. Corrugated fittings are often used to replace foam and other less environmentally friendly inserts and are generally a fraction of the price of traditional fittings. Another big advantage to using corrugated fittings is that they can be stored in a flat state requiring less space within your warehouse.
Most businesses from time to time will take a decision to display and promote their products to potential customers, usually in store and in prominent places. CDU’s (Counter Display Units) or FSDU’s (Floor Standing Display Units) are often required to do this and our in house design team can design bespoke and eye catching units specifically for your needs. To enhance the finished display they can be printed using flexographic techniques however, silk screen, lithographic and digital print options are also available depending on order quantities and the finish required. Other types of display boxes are also available and our design department will be more than happy to help and discuss your needs.
FAST AND ACCURATE PRODUCTION METHODS
Since our inception in 1992 The Box Factory has invested heavily in a diverse range of corrugated manufacturing equipment.
Equipment that we purchased in the early years was soon replaced as various technological breakthroughs in printing and feeding corrugated material came onto the market.
Today we are the proud owners of one of the most sophisticated, state of the art 4 colour Casemakers in the country. Capable of producing high quality cases, accurately and at high speeds, this large format, fast set, versatile machine has revolutionised the way we produce corrugated cases.
Underlining our commitment to growth, customer service, and forming part of our current investment plan, we recently acquired a large new VEGA multipoint gluer. This significant investment was one that has opened up new markets and provides a higher level of service to our customers, from a creative, quality, and lead time perspective. All of our manufacturing equipment is linked together via two fully automated pallet transfer lines optimising the latest available materials handling technology from Mosca and Emmepi.
A highly sophisticated and incredibly flexible computer software system (SPOCS) tracks all materials throughout the factories, incorporating real time reporting of job status and operator feedback. Touch screens are fully utilised in all the factories and warehouses to enable the control and collection of accurate and concise manufacturing and storage data.
ELIMINATE SOME CONSIDERABLE COSTS BY TAKING ADVANTAGE OF OUR MANUFACTURING AND STORAGE FACILITIES.
It's a simple case of maths...
If 10% of a 25,000 sq ft factory is taken up with the storage of packaging and the average letting rate per sq ft is £5.00, then this space is costing you £12,500 per annum!!
Why not have 2,500 sq ft of extra production space?
Our fleet of modern, sign written, dedicated vehicles driven by our own experienced drivers can be contacted by our office, or our customers, at all times. Pin point accuracy is obtained via our internal vehicle GPS tracking system when required. Our vehicles range in size and capacity from curtain sided articulated lorries capable of shipping 60 pallets at a time through to large, rigid, curtain sided lorries and quick response vans. All of our lorries are fitted with tail lifts should they be needed.
Our drivers are fully versed in the operation and procedures of JIT and Kanban deliveries, which are successfully operated with well over 70% of our existing customers.
Our environmental responsibility is something we take very seriously, as an individual business and as a global industry. At The Box Factory we ensure we do everything possible to minimize our own carbon footprint. This is apparent from many aspects of our business and includes our policy of only purchasing raw materials from managed and certified ”green” suppliers, right down to the recycling of our own paper drinking cups!! Our commitment to the continued challenges of reducing our impact on the planet has become part of our everyday internal systems. This is enforced by our accreditation to ISO 14001: 2004 for Environmental Management.
If you would like to learn more please do not hesitate to contact us.
IN THE UK AS AN INDUSTRY WE REGULARLY RECOVER OVER 80% OF ALL MATERIAL PRODUCED YEAR ON YEAR
THE HIGHEST OF ANY INDUSTRY SECTOR
We will plant a fruit tree in the Forest of Hearts for every £50K of order we receive
That’s about 250 trees per year
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Having continuously supplied corrugated products to a wide range of industries from the automotive to medical and food for over 23 years, we have been able to develop our internal management systems (IMS) to deal with the ever stringent and demanding requirements placed on us in today’s ever changing market place. This has been reflected in our successful and ongoing accreditation to ISO 9001:2008 (Quality Management), ISO 14001:2004 (Environmental Management) and in May 2011 we obtained full accreditation to OHSAS 18001:2007 (Health & Safety Management). Added to this list, in January 2016 we obtained accreditation to the BRC (British Retail Consortium) Packaging and Packaging Materials Standard. This achievement consolidates our commitment to the protection and wellbeing of our customers and workforce.
Being fully committed to improving all aspects of our business we are constantly looking for new and innovative ways of achieving sustained excellence. With continued investment in machinery, new technologies, our environment and most importantly our people, we truly believe in continuous improvement to ensure the future growth and development of our business.
HEALTH & SAFETY MANAGEMENT