Case study
World renowned window and shading manufacturer
A company whose name we unfortunately cannot disclose, and which is one of the world’s leading manufacturers of skylights, approached us to produce a large number of boxes in 2023 . These were intended as a secure infill for KLT boxes.
The parent company of this company has been around since 1941. It sells and manufactures in more than 40 countries and employs 9,500 people worldwide. The company creates better living conditions for people all over the world, giving them access to daylight and fresh air with high-quality skylights. Its product range includes skylights, flat roof lighting products and a wide range of shading accessories, installation solutions and intelligent controls for the home. These products contribute to providing a healthy and sustainable indoor environment.
Demand: manufacturing of a large number of boxes in different sizes with antistatic treatment
The client was unable to find a catalogue solution. Therefore, he requested the possibility of producing thousands of customized boxes of larger or smaller sizes to fill a KLT box of 600 x 400 mm. He needed to divide the inserts into 2, 4 and 8 parts (see picture below). He required the boxes to have finger grips inside in all sizes so that they could be easily removed from the KLT.

Solution chosen: Hollow plastic with ESD treatment
As the boxes needed to store products sensitive to electrostatic charge, we chose 680 g/m2 hollow plastic with ESD treatment as the material. This anti-static material treatment has the ability to dissipate electrostatic charge and thus does not damage the stored parts.
We have ruled out the production of alternative cardboard ESD plastic due to the required box load of up to 8 kg/piece.
First step: customized packaging design and sample production
Our engineer designed the boxes and after client approval we produced samples in the following dimensions: 400x300x200 mm, 300x200x200 mm, 200x150x100 mm and 200x100x80 mm.

Production: A total of 8,245 boxes in six different dimensions
Despite various changes in the sizes and quantities of each type, we finally confirmed the order for:
- 400x250x200 mm – 490 pcs.
- 400x250x100 mm – 110 pcs.
- 200x150x100 mm – 3,130 pcs.
- 200x100x80 mm – 3 420 pcs
- 300x200x200 mm – 1 060 pcs
- 500x200x200 mm – 35 pcs
In total, we produced 8,245 boxes, which we filled the entire truck with and successfully delivered to the customer in the promised short interval of 6 weeks. The production to the dispatch of all pieces took 670 hours.
Result: satisfied customer and further production in 2024
As the client was satisfied with our service, he ordered further production of the boxes of selected dimensions from us in 2024. This was a quantity of 1,230 pieces of the same ESD material in the following dimensions:
- 400x250x100 mm – 380 pcs.
- 200x150x100 mm – 250 pcs.
- 200x100x80 mm – 600 pcs.
We worked 100 hours on this order and delivered it to the customer within 3 weeks.