Today, we’re gonna talk about our collaboration with Chun on paper trays. Chun derives from the Korean company “Chung Chun, Korea”. The specialty of this fast food restaurant is their signature Korean Rice Sausage. It is a delicious mix between modernity and the traditional “Kogo” (sausage on a stick coated and deep fried with batter, Korean corn dogs).
At the time Chun was established in Malaysia, they had only one restaurant. They then started looking for a local packaging supplier to provide them with their packaging for their delicious sausages.
Chun’s main problem when looking for their suppliers was that they wanted a customized packaging. As they were not yet really inked on the Malaysian market, very few suppliers were willing to offer them the type of packaging they wanted with a relatively low order volume and at a low cost.
When they came to foodabox, we first took time to understand and define very clearly their request and need. They were looking for a type of tray that can be used as a simple tray when used alone but can be used as a box when two are stacked in a different direction each. With this data, we offered them a tailor-made prototype of the solution we wanted to offer them (which none of the other suppliers had taken the time to do for them before). Thus, they were able to test and test the prototype tray in real conditions.
Once the prototype was validated, we were able to provide them with 30,000 fully customized trays according to their own wishes and requirements.
However, after some time they realized that the cost of these trays was too high for them. Indeed these trays require a lot of forming, so a lot of man power’s and therefore it increases prices exponentially.
Following this remark from our customers, we have completely redesigned the trays to minimize costs. So we went from a version where we needed to glue some parts to a die-cutting only version.
For version 2, we proceeded in the same way as version 1, i.e. we first presented a mockup to Chun so that they could do their tests in real condition and see if the packaging we were offering them was ok for them.
The only negative point of this version is that they have to do the forming. But, following the rework we did on this second version of the tray, we reduced the amount of paper used per product as well as the manpower needed. Thus, we have reduced the production cost by 2 compared to the first version of the tray, which represents a lot on large quantities ordered!
In addition to that, they wanted some of their packaging to be able to be taken away. We offered a type of cover that we can provide them for free. How? Well, simply by using the waste paper used to produce their trays. Indeed, the arrangement of the moulds on the paper implied that paper was not entirely used. By rearranging the layout, we were able to add cutting lids on the same sheet. Thus no additional costs and above all a better optimization of resources
The main challenges of foodabox have been to question and reinvent oneself. This, in order to satisfy the customer and perfectly meet his expectations. After the proposal of the 1st type of paper tray it was necessary to start all over again from the beginning and our production teams went to great lengths to propose the most economical solution possible.
Today, Chun continues to use the paper trays we provide them. They are focusing on their strong growth without the blow of their packaging being an obstacle to this. They have grown considerably in Malaysia since their first visit to Foodabox and have opened several new brands.