Table lamps — metal shade, arm and base

A lamp the customer carries out by the handle

Table lamps with a metal shade were reaching customers scratched, and leaving the showroom in a plastic carrier bag. One pack closed both issues: a die-cut box with a lid, a cut-out handle and an insert that keeps the shade away from the base.

Render of a printed kraft box with a die-cut handle next to a table lamp
01

Starting point

The maker sells table lamps of its own design: through its online shop, through interior stores and in its own showroom. The same lamp therefore ships by courier to the end customer, stands on a partner's shelf and leaves the showroom in the buyer's hand.

Until then each of those channels had a different pack: a universal carton with bubble wrap for shipping, and in the showroom a box plus a plastic carrier bag, because the box could not be carried. Three routes, three different faces of the brand, and none of them protected the shade the way it needed.

02

What the client was up against

A lamp is three different sensitivities in one product: a heavy base, a thin arm and a shade in lacquered metal. In a universal carton the base worked like a hammer — with every jolt it struck the arm or the shade, and the lacquer picked up scratches from its own bubble wrap.

A scratch on a shade is not damage a customer keeps quiet about. The lamp is bought as an object to be looked at, so the return comes back with a review — and in the showroom the lack of a handle meant a plastic bag that a brand designing lighting did not want to hand over.

  • A heavy base and a light shade in one box with nothing between them — the base destroyed the rest.
  • Bubble wrap scratched the lacquered shade instead of protecting it.
  • Three sales channels, three different packs and no consistent face of the brand.
  • A box without a handle forced a plastic carrier bag in the showroom.
03

Solution

Flexo folder-gluer machine on the production floor
The flexo folder-gluer. Pattern printing, handle die-cutting and gluing in a single pass — which is why every box in the run sets up and carries the same way.

We started with the interior. A board insert splits the box into a cell for the base and a cell for the shade, with the arm lying in a die-cut profile between them — none of the three parts can touch another, so the wrap became unnecessary. The shade only ever touches smooth board.

The box itself is a die-cut construction with a lid and a handle cut from the two lid flaps, which lock together into a single grip when closed. The same box ships by courier, stands on a shelf and leaves the showroom in the customer's hand. Single-colour print on brown kraft board gave the brand its pattern with no varnish and no laminate, so the whole pack goes into paper recycling.

  • Dividing insert: separate cells for the base and the shade, the arm in a die-cut profile.
  • Handle cut from the lid flaps — the box carries like a bag, with no extra carrier.
  • One box for courier shipping, the shelf and the showroom.
  • Single-colour print on kraft: the brand's pattern without varnish or laminate, all of it recyclable.
04

Result

0damages

across 3,000 lamps shipped during peak season

Through peak season the client shipped 3,000 lamps without a single report of a scratched shade or a bent arm.

Two of the three packs and all the bubble wrap disappeared from the warehouse. In the showroom the box with a handle became part of the sale — the customer carries it out by the handle, and the pattern on the carton does the advertising on the way home.

Project details

Industry
Lighting and interiors
Product
Table lamps — metal shade, arm and base
Construction
Die-cut box with a lid and cut-out handle, dividing insert, single-colour print on kraft
Scale
3,000 units in peak season

Facing a similar shipping problem?

Tell us what the product is and how it ships — you get a construction and a quote back, not a catalogue page.

Get in touch

Some client details are under NDA — cases are shown anonymously, but the numbers are real.

Let's talk about your packaging

Tell us about the product and how it ships — we'll pick the board, design the die-cut and prepare a quote.

Write to us

Three fields. We'll ask for the rest in our reply — we get back to you within one business day.

One is enough — we reply through the same channel.

The data controller is Emtek (Częstochowa). We use the data from this form only to answer your enquiry. Details in our privacy policy.

Company details

Company name
PPHU Emtek
VAT ID
949 188 38 34
Address
Bojemskiego 10A, 42-200 Częstochowa, Poland
Opening hours
Monday - Friday, 7:00 AM - 3:00 PM

Bojemskiego 10A, 42-200 Częstochowa, Poland

The map loads from Google Maps servers, which may store their own cookies on your device.

Open in Google Maps

Call us directly

If you'd rather settle it right away, pick someone from the team.

Artur Biegański

Artur Biegański

Sales department

The office is my second home — I'll reply before your coffee goes cold. I look after every customer, from a single parcel to a full truckload.

Maciej Pilicki

Maciej Pilicki

Sales department

You'll find me on the road more often than at my desk. I'll drive over, see the product in person and pick packaging that actually gets it there in one piece.

Marta Lisiewicz

Marta Lisiewicz

Orders

Your order lands on my desk and I don't let it out of sight. I'll confirm the date and tell you when the goods will be at your door.

Paweł Matysiak

Paweł Matysiak

Owner

I built this company up from its first machine and I still sit down at the table myself for the bigger contracts. Need regular deliveries or unusual terms? Write to me — you'll get an answer on the spot, not after it's been passed around three departments.

Michał Kozieł

Michał Kozieł

Production manager

I watch over your order from picking the board, through the cutting die and printing, to the last check before loading. I plan the machine schedule, so the deadline is on my head. Got a prototype or a die-cut nobody wants to take on? Call me — those are my favourite.