Lamplight Farms Cuts Labor Costs with Molded Pulp

Lamplight Farms Inc., a Menomonee Falls, Wisconsin-based company manufacturers Clean Burn Tabletop Firepieces and TIKI® Brand Torches. They are part of the W.C. Bradley Co. family of companies, along with other leisure and lifestyle brands including Char-Broil® and Zebco®.

The Challenge: Lamplight had been purchasing a corrugated die-cut protective “cap/tray” that required assembly for the high-volume TIKI® Torches. This was causing an assembly bottleneck due to the time it took to fold these. Just as important, the folding repetition was causing health-related concerns among employees.

The Solution:  Rollguard developed a custom molded pulp packaging solution that does not require any folding or assembly. It can be easily and quickly attached to the torch, and remains cost-effective and environmentally-friendly.

Results: The packaging process was accelerated with the change from corrugated to the molded pulp. The repetitive motion that it took to assemble the corrugated material was eliminated and labor time diminished greatly. The best news of all were no reports of issues with Carpal tunnel with the molded pulp solution!

Custom Molded Pulp Packaging
After: Custom molded pulp solution
Product with a Need for Molded Pulp Packaging
Before: Corrugated die-cut “cap/tray”
Molded Pulp Packaging

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