Country: Brazil

Category: Household

The Pérola project is a structural packaging redesign for four heavy, premium metal fittings — wall tap, basin tap, wall faucet mixer, and basin faucet mixer — that replaces four separate cartons with die-cut paper cradles with one universal box plus a molded-pulp cradle. More than a new box, it is a system redesign: assembly, handling, stocking, and waste were rethought so the pack works better for people, operations, and the environment.

Before, each SKU used a paperboard box with an integrated cradle. In practice, any assembly mistake forced the entire pack to be discarded, generating immediate waste and cost. Assembly was slow, the system hard to understand, and variation on the line pushed unit costs upward. In transport, the cradle failed to shelter and protect adequately; heavy components could rub or shift, leaving dents and marks on glossy/matte finishes — unacceptable results for premium metalware that customers expect to receive pristine.

The core innovation is a universal molded-pulp cradle that fits two distinct geometries (curved spout for basin, straight spout for wall) and all four SKUs. Engineered ribs, pockets, and separation planes distribute weight, isolate delicate surfaces, and lock parts in place. This prevents friction, rattling, and impact damage while guiding clear, intuitive placement that reduces errors and rework.

Operationally, shifting from four SKU-specific boxes to one reference (4→1) simplifies purchasing, inventory, picking, and replenishment. On the line, fewer parts, folds, and interfaces make the process faster and more ergonomic. In controlled pilots, the redesign halved assembly time (–50%) and reduced unit pack cost by 21%, freeing productive hours, lowering capital tied up in packaging, and reducing stoppages caused by missing variants. Because the cradle prevents damage, returns and scrap drop, cutting material, transport, and energy waste across the chain.

Socially, the project lightens the workload for operators. The new sequence is cleaner and easier to execute, with less force, fewer repetitive corrections, and fewer decision points—real gains for training, safety, and morale. For customers, products arrive intact and the unboxing feels premium and tidy, reinforcing the Pérola line’s value.

Environmentally, molded pulp is made from recycled fiber and is recyclable, biodegradable, and compostable after use. Consolidating four boxes into one cuts printing, setup, and obsolescence, while better protection prevents damage-related reshipments. The cradle’s geometry is mass-optimized to deliver performance without over-packaging, and components were specified for easy material separation at end of life.

Brand and trade also benefit. The artwork now promotes the line (SKU identified by label), building coherence on shelf and reducing redesign overheads. One pack architecture standardizes pallet patterns and shelf blocking, making merchandising and replenishment more reliable.

In short, Pérola redesigns the system, not just the box. It protects heavy, delicate products better, cuts time and cost, simplifies logistics, reduces waste, and improves people’s work—all with a circular, fiber-based solution that scales across the line.