The Challenge
HellermannTyton manufactures precision-engineered cable ties used across construction, energy and industrial sectors. For some of their products, retaining a specific level of moisture in the packaging is essential to prevent brittleness and ensure performance.
It was reported that moisture was escaping the cable packaging during transit causing poor performance of the cable ties. The solution at the time was to manually repack cable ties into laminated outer bags, adding labour, cost and non-recyclable packaging products.
The process slowed production, generated additional packaging, and went against their wider sustainability objectives. HellermannTyton needed a new solution, one that would preserve product integrity, reduce handling and eliminate the use of laminated films going to landfill.
What we did
Duo worked closely with HellermanTyton’s Global Packaging Development lead to design an industry-first moisture-retaining solution. Made with 30% recycled content, the new custom design eliminated the need for a laminated secondary bag and replaced a multi-step repackaging process with a single, fully recyclable bag that integrates directly into their production line.
The solution delivered better moisture control, supported operational efficiency and helped HellermannTyton reduce their environmental impact all while meeting the strict technical standard the product demands.
The Results:
The impact was immediate and substantial:
- Over 160,000 laminated bags removed from the supply chain annually.
- Significant cost savings were made from eliminating secondary packaging.
- Improved machine efficiency due to reduced manual handling.
- Enhanced product performance through better moisture control.
“Through dedication and commitment to create what is an industry-first solution, Duo has helped us to tackle a problem, using their expertise and experience to turn that into a solution by understanding our needs and manufacturing capabilities. As a result, it has delivered unbelievable results.”
Maddie Maudsley, Head of Procurement, HellermannTyton