Client: Wookey Hole Cave Aged Farm House Cheddar 
 
Introduction: 
 
The client approached Atlas Packaging looking for a shelf ready packaging design that enhanced and fitted into their current branding, reduced production costs whilst being suitable for transit.  
 
Video:
 
 
BRIEF: REDUCE COST OF LITHO PRINTED PACKAGING
 
The original litho printed shelf ready packaging for the Wookey Hole Cave Aged Farmhouse Cheddar pack held good shelf-presence, however the company wanted a re-design of the new packaging to ensure that the colour of the packaging was more consistent across the range and the brand. Furthermore, the client also found that the litho-printed boxes also incurred high costs, something that they wanted to reduce. They also wanted to try and reduce their lead times with their choice of packaging.  
 
SOLUTION: INTRODUCE FLEXO TO THE EQUATION
 
Atlas Packaging suggested to change the original litho-printed box with a flexo-printed box for a more cost effective and high quality product. 
 
Cost Effective
 
Although the lithographic process does produce a high-quality product, the process of flexography allows for this high quality to be matched whilst significantly reducing the price and time it takes to produce the desired quantity of packaging. 
 
Improvement in Process 
 
The design team reworked the original artwork to make it more “flexo-friendly” for the flexo printing process. With recent investment in the £2.5 million CUIR MK III flexo post print machine; Atlas could produce higher quality flexo printed packaging for the client. The CUIR MK III has more printing stations with the specification to complete a 6-colour job in one pass. Conducting the job on this machine also resulted in tighter registration resulting in a sharper image for the client. 
 
BENEFITS OF LITHO TO FLEXO:
 
The Flexo Box enhances the main key features of the old Litho Box with a massive cost saving of around 35% on a like to like order.  
 
Many of the value-added processes in lithography production require long setup times. Switching to flexo allowed for a high-speed production and a reduction in the waiting times for the client. 
 
Switching to the CUIR Rotaflexo machine also resulted in tighter print registration. 
 
 
About Wookey Hole Cave Aged Farmhouse Cheddar  
 
Wookey Hole Cave Aged Cheddar is a multi-award cheese made at Ford Farm in Dorset; then matured in the Wookey Hole Caves in Somerset.
 
For further information on their range of cheeses visit http://www.caveagedcheddar.co.uk/