Custom Packaging Solutions: Why On-Site Visits Make the Difference

When it comes to packaging solutions, guessing is not good enough.  At Badger Paperboard, we take the extra step and come to the problem to help find the perfect shipping solution. 

Through our proactive on-site visit approach, we are not just providing quotes – we are diagnosing challenges, observing processes, and creating a custom paperboard packaging solution.

Step 1: Pre-Visit Research 

Once our team is notified either by phone, email or request a quote through our website, we start with pre-visit research to gather key information. For example, if someone shares that “the robotic equipment is picking up more than one palletizer sheet at a time,” that immediately signals to our team that there could be challenges with sheet separation, stacking accuracy, or static build-up.

Each situation is unique, and our expert team with decades of combined experience works to arrive at any site informed and ready to dig deeper and uncover the root cause of an issue, not just the symptoms.

Step 2: Understanding Your Packaging Challenges

The main focus of our second step is simple – listening and asking the right questions to clarify the challenges at hand.  Our goal during this step is to uncover what is not working and why, using questions like: 

• What issues are occurring during production? 
• How long has this issue been happening? 
• Are there any recent changes to materials or equipment? 
• What impacts the operations’ efficiency? 

Going back to our example of robotic equipment picking up too many palletizer sheets at a time, we would ask questions about material quality, stacking accuracy, or cut quality. Understanding how packaging materials and automatic equipment work together is key to identifying the precise solution. 

This step is not about offering a generic fix. It is about building an accurate picture of the problem and building the best plan of action to move forward and streamline an operation.

Step 3: An On-Site Visit

The third step involves one of our team members conducting an in-person visit to observe the issue firsthand and gather the exact data needed to design the perfect solution. 

The on-site portion of our process involves a technical visit, not just a general walkthrough of the facility. We come prepared with essential tools like micrometers, tape measures, and more to assess aspects like the exact dimensions of your product.

Our team will observe how materials interact with equipment, operators, and the overall workflow. Again, if there are reports of robotic picking inconsistencies, we will examine how the sheets are stacked, how they are presented to the robot, and whether any dimensional or environmental issues are affecting their efficiency. 

This is the stage where our hypothesis meets real-world application. Based on our findings, we will assess whether adjustments like sheet thickness, cut precision, or stacking methods could improve efficiency, and determine whether a product like our Automated Palletizer sheets are the right fit for your operation.

Step 4: Packaging Sample Development

Once we have gathered all of the necessary data and measurements during the on-site visit, the next step for our team is to produce custom samples based on our findings. These solutions are tailored to the exact specifications required for the process, equipment, and quality expectations. 

Depending on the complexity of the sample and solution, samples typically arrive within two to four weeks. During this time, our team is available to answer any questions about the next steps. 

Once a sample arrives, we communicate and work with the customer to ensure that the sample works appropriately and as expected. We do not consider our job complete until the solution resolves the issue it was intended to resolve.

A True Partnership 

Every project is approached with a technical and proactive mindset, a structured process, and a focus on long-term performance for operation. From initial research and on-site evaluations, our team is passionate about engineering the right product for every unique need. 

Let us eliminate the guesswork. Reach out today!