We’ve a head for boxes

Leamington Spa based corrugated packaging manufacturer, The Box Factory, continue to go from strength to strength, now offering FSC certified product to all customers.

The Box Factory, established in 1992, designs and manufactures corrugated packaging, in high volumes, for all industry sectors. They offer a unique stock holding facility that differentiates the company from many other major suppliers in the industry.

Currently employing 85 people, 2019 sees the next stage in a 5 year investment programme which has included major developments throughout the business. This all started with the acquisition of a new 40,000 square foot manufacturing facility to house 3 ‘mainline’, industry leading machines with fully automated palletising and material handling equipment. This was in addition to the existing 70,000 square foot facilities already in use. Having achieved an “AA” rating for the BRC Global Food packaging accreditation as part of the plan, the new manufacturing facility represented a ‘super-efficient’ manufacturing environment to ensure service, price and quality are at the perfect levels for our customers. Recent FSC certification adds to the offering by guaranteeing that our customers receive packaging that originates from a sustainably managed or recycled source.

An additional 10,000 square foot warehouse was also added at the end of last year to further support the ‘Next Day Stock and Serve’ service which increased storage capacity to 5,500 pallets of finished goods. The systems in place to manage stocks allow customers to save considerable warehouse space whilst feeling confident that stock levels are constantly monitored and managed. Extreme fluctuations in box usage and emergency requirements are all catered for.

Ongoing developments in relation to software systems are a core part of the process and all of the key functions of the business are integrated to ensure a smooth flow of information. A “paperless” factory environment with Shop Floor Data screens allows live access to production information, ensuring that process waste, downtime and maintenance requirements are constantly monitored.

The recognition of a demand for multipoint glued boxes led to the acquisition of a speciality gluer to offer ‘self-erect’ box styles, which has helped many customers to save time (and money) in their processes. This is all supported by 4 full time designers, offering bespoke designs and prototyping on a New DYSS X5 CAD Table from AG/CAD. A new purpose built design centre is currently under construction, which is due for completion in September this year. This will undoubtedly provide a creative and professional environment for designers and customers alike.

“We recognise that every area of the business must continually develop and evolve as part of our drive to offer the absolute best service to our customers. We are all incredibly proud of our achievements to date and are constantly looking forward to continuing the development of our team, our manufacturing capabilities and overall business infrastructure”

Neil Price, Managing Director The Box Factory

When print requirements are a particular consideration, a Rexson ink kitchen mixes any colour, specific to the material substrate, on demand. A Spectrophotometer then allows the checking of colours to ensure the required Delta E score is achieved, something many large brands and retailers now expect.

T: 01926 430 510 | E: sales@boxfactory.co.uk | www.boxfactory.co.uk