Case Study: Terapaq’s Role in Transitioning a Major Retailer to Domestic Manufacturing

A Strategic Shift to Domestic Manufacturing

In today’s fast-paced and cost-sensitive market, businesses are increasingly seeking ways to streamline supply chains, reduce lead times, and achieve greater control over production. Terapaq recently partnered with a major retailer to successfully transition over 30 million pre-made units of goods from Chinese manufacturing to domestic production. This case study highlights how Terapaq’s expertise in material analysis, manufacturing efficiency, and collaborative problem-solving played a pivotal role in achieving this ambitious goal.

Challenge: Balancing Performance, Cost, and Timelines
The retailer faced multiple challenges in transitioning their production to the United States:
– Material Optimization: The Chinese-manufactured films used for packaging needed to retain essential barrier properties (protection against oxygen, moisture, and UV light) while meeting the retailer’s price targets.
– Production Timelines: The project required a rapid turnaround, with 5 million units of roll film needed within just three weeks.
– Collaborative Coordination: The transition involved aligning with a contract packager to ensure seamless integration of materials into the production process.

Terapaq was tasked with analyzing the existing materials, proposing an alternative solution, and ensuring the tight deadlines were met without compromising quality.

Solution: Terapaq’s Expertise in Domestic Manufacturing
1. Material Analysis and Optimization 
  Terapaq’s team meticulously analyzed the materials provided by the Chinese manufacturer to identify key performance requirements, including barrier protection and durability. Leveraging our expertise in multi-layer film technology, we developed an optimized alternative that: 
  – Retained the necessary barrier properties to protect the product. 
  – Met the retailer’s price target by utilizing cost-effective yet high-performing materials. 

2. Seamless Collaboration with Contract Packager 
  To ensure the success of the project, Terapaq worked closely with the contract packager responsible for assembling the final product. This collaboration involved: 
  – Aligning material specifications with the packager’s equipment capabilities. 
  – Synchronizing production timelines to meet the retailer’s delivery goals. 

3. Rapid Production and Delivery 
  Despite the complexity of the project, Terapaq successfully manufactured and delivered 5 million units of printed , laminated and slit roll film within just three weeks. This achievement was made possible by: 
  – Utilizing our industry contacts to obtain necessary materials rapidly  
  – Implementing AI-driven analytics to optimize production efficiency and minimize downtime. 
  – Streamlining our operations to prioritize this high-stakes project.

Results: A Successful Transition to Domestic Manufacturing
The collaboration between Terapaq, the retailer, and the contract packager yielded remarkable results:
– Cost Efficiency: The optimized material solution met the retailer’s price target without sacrificing quality. 
– Accelerated Timelines: Terapaq’s ability to deliver 5 million units of printed, laminated and slit rollstock within three weeks enabled the retailer to maintain their supply chain continuity during the transition. 
– Enhanced Control: By shifting production to the United States, the retailer gained greater oversight of their supply chain, reduced lead times, and improved responsiveness to market demands. 

Key Takeaways: Terapaq’s Value as a Manufacturing Partner
This project underscores Terapaq’s ability to:
– Analyze and optimize materials to balance performance and cost. 
– Coordinate seamlessly with external partners to ensure project success. 
– Deliver high-quality products within tight timelines, thanks to our advanced manufacturing capabilities and data-driven approach. 

By leveraging our expertise in flexible packaging and sustainable manufacturing practices, Terapaq is helping businesses transition to domestic production while achieving their operational and financial goals.

Conclusion: Partnering for Success
Terapaq’s role in this project highlights our commitment to providing innovative, efficient, and sustainable packaging solutions. Whether analyzing materials, optimizing production processes, or meeting ambitious deadlines, Terapaq delivers results that drive value for our clients. 

For more information on how Terapaq can support your packaging needs, contact us at [email protected] or visit Terapaq.com.