Tag Archives: Lesters

News, Packaging

Lesters looks to green the supply chain with new automotive offer

Delivering a sustainable supply chain is at the heart of a new dedicated offer launched by Burntwood-based Lesters.

The UK’s leading manufacturer of high-performance packaging has introduced a specialist ‘automotive’ division to work even closer with its growing customer base that features OEMs, first and second tier suppliers and third-party logistics providers.

A team of experts in design, sales, marketing, and logistics are on hand to help clients reduce their carbon footprint through supply chain optimisation and the replacement of plastics and foams with sustainable packaging mediums.

“Our automotive experience, expertise and consultative approach go beyond the product to help identify and create value in supply chains…whether that is reducing end-to-end costs, increasing efficiencies or boosting sustainability,” explained Mark Aucott, Automotive Business Manager at Lesters.

“The sector is complex and requires a circular approach and that is where this new offer really comes into its own. From initial consultations and identifying different types of material to testing and tapping into our expansive prototyping capability”.

He continued: “By employing this method, we’ve been able to help several of our automotive customers potentially reduce their supply chain costs by up to 25% – a saving that can run into the hundreds of thousands of pounds!

“We also have the added benefit of Lesters Logistics – our very own supply chain capability that closes the loop for the customer and can provide next day delivery, ‘stock and serve’ and ‘pick and pack’ services.”

Lesters has enjoyed a major period of expansion, with over £7m invested in creating an ecosystem around its core large format high performance box manufacturing capabilities and capacities.

This is supported with market leading design and innovation facilities, aligned with both theoretical and physical pack testing to support product development and testing before implementation.

Thanks to its two TCY Casemakers, which are capable of printing in three colours, the company has the capability to run over 465,000 large format, sustainable cases per day.

On the automotive side of the business, Lesters offers heavy duty packaging for extreme protection of intricate components and valuable items, and ‘Easy Pick’ folding pick bins that don’t require gluing or staples, making them easy to assemble.

It also has a strong track record in bespoke die cuts, providing a wide range of style and board grades, as well as a host of tailored options that offer a unique combination of strength and weight saving features.

Mark, who has been involved in the automotive industry for the last twenty years, went on to add: “Electrification is something that everyone is talking about, and we have already developed innovative packaging that has reduced costs in their supply chain.

“There is also major growth in the field of new automotive start-ups, where our expertise in setting up packaging and packaging lines can ensure a smooth transition into start of production (SOP).”

One recent example of Lesters capability in this field is its work with Rolec, the UK’s leading manufacturer and supplier of EV chargepoints.

With sales for electric cars going through the roof, the customer had seen a massive increase in demand for its products, yet the packaging hadn’t really kept up with its innovation and growth.

Led by Design Manager Greg Burton and his three-strong team, Lesters came up with a new solution for its Zura intelligent charger that was optimised for the courier service, removed all plastic from the equation and upgraded the end user ‘opening’ experience.

Following numerous prototypes, the client settled on a unique one-piece design using a high-quality print large format box, with the print carried through the internals and the box featuring integrated fittings.

The packaging has reduced the number of SKUs from 4 to just 1 and is suitable for the complete product range, including the 5-metre tethered, 5m double tethered and 10m single tethered options.

For further information, please visit www.lesterspackaging.co.uk

Midlands News, News, Packaging

Large packaging specialist opens second warehouse after 120% sales boom

Lesters has announced it has invested £100,000 into the opening of a second warehouse to help it cope with a 120% increase in orders.

The large packaging specialist, which has recently recruited 15 new staff, has fitted out the 25,000 sq ft facility near its headquarters in Burntwood with flexible racking options meaning it has enough space to store over 2000 pallets.

This latest move, coupled with its existing Lesters Logistics facilities, means the company can now offer 47,000 sq ft of storage space, 20,000 sq ft of floor storage space and 3,000 pallet spaces.

It will help the firm bring its storage of its stocked items in-house, reducing lead times and ensuring even better customer service for clients in the aerospace, automotive, pharma, renewables and online shopping sectors.

A new Warehouse Manager has already been appointed to oversee the additional operation.

“We have a three-year expansion plan that will see the business move to £25m of annual sales and getting more of our stock under our control is an important step in making that happen,” explained Billy Hutchinson, Managing Director of Lesters.

“It was previously outsourced and that didn’t give us the flexibility we needed, especially with more customers coming online by the day.

“Taking on Unit 12, a stone’s throw from our current factory, gives us a lot more space for our stocked items, as we are increasing our ability to offer more ‘stock and serve’ options to clients.

“Supply chain challenges are a big talking point for our customers. Recent events and uncertainty have created a need for many UK businesses to increase their security of supply for the critical packaging lines they require. This will help us provide the security they are looking for.”

The last twelve months have been transformational for Lesters, the UK’s leading specialist in big box packaging for the aerospace, automotive, bike manufacturing, mail order and third-party logistics space.

Boosted by a significant surge in online shopping, the Burntwood-based company has seen sales soar to £16m and its workforce increase to 60 people.

The growth has been driven by investment in skills and, importantly, a £7m investment programme that has resulted in the installation of a new TCY Jumbo Casemaker (first of its type to be operational in the UK) and the impending arrival of a TCY N6 3 colour casemaker machine.

These acquisitions have helped the company reduce lead times and increase capacity from a combined 180 boxes per minute to over 360 – essential if it is going to meet planned expansion targets.

“Add all of this together and it means we are the very top of our industry when it comes to performance and supplying corrugated boxes, large format, heavy-duty cases and bespoke packaging to clients in the automotive, aerospace, bike manufacturing, mail order and third-party logistics space,” added Billy.

“We are exploring a way of creating our own eco-system where we have full control over the whole of the packaging production process, from print ink and design, right through to distribution through Lesters Logistics in Nuneaton.

“That was our first acquisition by the current management team, with plans in place to look at other complementary businesses that give us greater market share, access to new customers and wider geographic reach.”

Another big opportunity for Lesters has been the introduction of the plastic packaging tax on April 1st.

This means manufacturers or importers of plastic packaging could be hit by a £200 tax for every per metric tonne of plastic packaging, a great incentive for them to explore alternative forms of packaging, including cardboard boxes.

Billy concluded: “We have an action plan in place to offer new and existing clients the opportunity to find alternative solutions and, importantly, become a more sustainable business in the process.”