Develop a bespoke production line in order to cope with the unique requirements of the task, before then automating the process to reduce the price per unit to an acceptable level.
A material manufactured from biodegradable starch that also used low-toxicity inks was used that had never before been used as a primary form of decoration. It was a real challenge to achieve the desired high quality finish for the products when using such a difficult material.
Not only did CCE commission Mailway to shrink sleeve 2.5 million bottles in just eight weeks, the challenge lay in the bottle’s unusual shape, as the hand grip area made it extremely difficult to get a clean smooth sleeve finish to follow the contours of the bottle.
The unusual shape of the products made the job a great deal more challenging, compared to standard rectangular packs which have been used in the past.
For this project, the glass had a unique bevelled base which required a slightly different approach from the Mailway team.
Tasked with the design of the packaging to display the product in an eye-catching way, Mailway also had to ensure the final solution would be cost-effective.
The Mailway team realised the moment they saw how the glasses were meant to be packed that there was no way the job could be done within the parameters of the budget put forward by McDonalds, so finalising a cost-effective solution was vital.
With the high volumes being handled, Mailway needed to develop an effective high-speed automated process of printing and inserting the coupons directly into the packaging, without impacting on tight manufacturing deadlines.