Case study · Pool & spa chemicals

The pouch already worked.

Now the ordering does too.

A growing pool and spa chemical company had packaging that performed well but had to be bought in huge quantities. RCI built a production plan that kept the same pouch and cut minimum orders to as low as 5,000.

A growing pool and spa chemical company had packaging that performed well but had to be bought in huge quantities. RCI built a production plan that kept the same pouch and cut minimum orders to as low as 5,000.

5,000

5,000

5,000

pouch minimum order, down from huge runs

pouch minimum order, down from huge runs

0

0

0

changes to the pouch itself

changes to the pouch itself

01. Sound familiar?

Too much packaging, bought too early

The company packed its products in high-quality VMPET and PE stand-up resealable pouches. The pouch was never the problem. High minimum order quantities meant committing to far more packaging than it needed, which made it hard to add new SKUs or test new products.

The company packed its products in high-quality VMPET and PE stand-up resealable pouches. The pouch was never the problem. High minimum order quantities meant committing to far more packaging than it needed, which made it hard to add new SKUs or test new products.

›

You’re sitting on more packaging inventory than you need

›

Minimums make it hard to launch or test new SKUs

›

Your packaging works, but the way you buy it doesn’t

02. What made it tricky

Smaller runs usually cost more per pouch

In flexible packaging, lower quantities can quickly drive up the cost per pouch. RCI had to keep the barrier properties, construction and resealable closure the product needed, and still protect the economics of the higher-volume SKUs.

In flexible packaging, lower quantities can quickly drive up the cost per pouch. RCI had to keep the barrier properties, construction and resealable closure the product needed, and still protect the economics of the higher-volume SKUs.

03. What RCI did

Matched the print method to the run size

We weren’t tied to one printing technology. Digital printing made small runs affordable without the setup costs of traditional printing. As volumes grew, gravure printing delivered high-quality reproduction at a better price for larger runs. The client now buys the way its business works, not the way one plant works.

We weren’t tied to one printing technology. Digital printing made small runs affordable without the setup costs of traditional printing. As volumes grew, gravure printing delivered high-quality reproduction at a better price for larger runs. The client now buys the way its business works, not the way one plant works.

01

Inventory flexibility

Lower minimums let the company buy closer to real demand.

02

Production efficiency

Digital for short runs, gravure for long ones.

03

Packaging performance

Same construction, barrier and resealable closure.

What we made

›

Stand-up resealable pouches

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Digital print program for short runs

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Gravure print program for high-volume SKUs

AquaDoc Professional pH Increaser 10 lb black pouch on a steel workbench in a pool equipment room
AquaDoc Professional Chlorine-Free Shock 10 lb pouch on a step beside a steaming hot tub at dusk
Borate Plus 5 lb stand-up pouch on a white poolside table next to a lounge chair
PuriTech Stabilizer 10 lb white stand-up pouch on a concrete plinth
Pool Day pH Increaser 10 lb blue stand-up pouch on the edge of a backyard pool

04. What it did for the business

A packaging program that flexes with the business

The company can introduce new SKUs and test new products without taking on large packaging commitments, while its best sellers still get high-volume pricing.

The company can introduce new SKUs and test new products without taking on large packaging commitments, while its best sellers still get high-volume pricing.

05. What it saved them

Less money tied up in packaging

Right away

Minimum orders dropped to as low as 5,000 pouches, so the company no longer has to buy far ahead of demand.

Long term

Each SKU runs on the print method that fits its volume, so small runs stay affordable and large runs keep their economics.

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