Inspired by Precision: How Arclad Achieved 100% Product Protection

Arclad, a leading Colombian manufacturer of adhesive label paper rolls, needed to enhance the protection of its products throughout the supply chain. Its existing spider-style end caps left critical gaps in the packaging, increasing the risk of damage during handling, transportation and storage. At the same time, supply disruptions from its incumbent supplier were creating delivery delays and affecting service levels. Arclad required an innovative packaging solution capable of delivering superior protection, streamlining operations and securing a dependable supply to support its commitment to customer satisfaction.

Working closely with Arclad, the Smurfit Westrock team conducted a collaborative process to understand the company's operational needs and product protection requirements. Through plant assessments and co-creation sessions, inspiration came from an unexpected place: the camera lens diaphragm. Its circular, overlapping blade mechanism provided the concept behind a new packaging design engineered to maximize protection without compromising efficiency. The solution resulted in an innovative wrap-around end cap with precision slit cuts that enable controlled flap overlap, ensuring a secure uniform fit around each roll while maintaining the strength and integrity of the corrugated structure.

By combining innovation, collaboration, and engineering expertise, the solution generated measurable value for Arclad: 

• Delivered 100% product protection with a secure fit that eliminates voids and reduces the risk of damage.
• Achieved zero waste in production while maximizing material efficiency. 
• Reduced lead times to 5 days, strengthening supply reliability and delivery performance. 
• Increased plant productivity and operational efficiency through a smarter packaging design. 
• Improved the customer experience by ensuring products are delivered fully protected and in excellent condition.