Table of Contents
Project Background: The Weight of Success
In the competitive beverage market, visibility is everything. A fast-growing energy drink brand based in the UK approached One Plus Display with a critical mission: they needed to launch a nationwide promotion across 500+ supermarkets. Their product—500ml liquid cans—is heavy, requiring a display solution that offers both high visibility and extreme structural integrity.
The client needed 2,000 units of custom Cardboard Floor Displays. However, this wasn’t just about printing a logo; it was an engineering challenge. Each display needed to hold 4 tiers of cans, with a total load weight exceeding 50kg (110 lbs), while withstanding the busy, often wet environment of grocery store aisles.
The Challenge: Why Standard Displays Failed
Before contacting us, the client had suffered a failed rollout with a previous supplier. That experience highlighted two major pain points that we needed to solve:
- Structural Collapse: The previous supplier used standard BC-flute corrugated board. Under the immense weight of the liquid products, the shelves bowed and eventually collapsed within 3 days, causing product damage and safety hazards in stores.
- Moisture Damage: Supermarket floors are frequently mopped. Standard Corrugated Display Stands act like sponges, absorbing water from the bottom. This caused the bases to rot and the entire structure to tilt dangerously.
The client was clear: “We need a POP Display that looks like cardboard but acts like wood.”
Our Solution: Structural Engineering Meets Retail Reality
At One Plus Display, we don’t just manufacture; we engineer. Understanding the physics of Heavy-Duty Cardboard Displays, our team developed a three-part solution to guarantee stability.
1. Material Upgrade: The BE-Flute Advantage
We abandoned standard materials and upgraded to high-density BE-Flute Corrugated Board. This material offers a tighter wave structure, providing superior crush resistance. We further reinforced the side panels with a double-wall construction, creating a rigid skeleton capable of supporting vertical load pressure.
2. The “Invisible” Metal Support System
To ensure zero sagging on the shelves, we integrated hidden metal support bars beneath each tier. These bars take 80% of the weight stress off the cardboard.
- The Benefit: The display retains the eco-friendly, cost-effective appearance of a Cardboard Display, but possesses the internal strength of a permanent fixture.
3. Waterproof “Water Guard” Base
To solve the mopping issue, we designed a custom clear PVC base tray that sits at the bottom of the display. This 2-inch “Water Guard” creates a barrier between the wet floor and the corrugated paper.
- The Outcome: Even if the floor is soaked during cleaning, the structural integrity of the display remains compromised, extending the display’s lifespan from 2 weeks to 3 months.
The Result: 0% Failure Rate & Maximum Sales
The new prototype passed a rigorous 72-hour weight test in our factory before mass production. Upon deployment to UK retailers, the results spoke for themselves:
-
- Durability: Over the 12-week campaign, the client reported a 0% structural failure rate across all 2,000 units.
- Retailer Satisfaction: Store managers praised the displays for being sturdy and easy to clean around, securing better floor placement in high-traffic aisles.
- Sales Uplift: With the displays remaining upright and attractive for the full duration of the campaign, the client saw a 35% increase in sell-through volume compared to previous campaigns.
Ready for a Robust Display Solution?
Don’t let a collapsing display damage your brand reputation. Whether you are selling heavy beverages, tools, or bulk food items, One Plus Display has the engineering expertise to create Custom Cardboard Displays that can handle the weight.
Contact us today for a free consultation and structural design proposal for your next retail project.
