Project Overview

Glen Dimplex, a world-leading manufacturer of high-quality domestic appliances (including Morphy Richards, Belling, Britannia and Stoves) required protection for their products in transit. With over 8,000 appliances leaving just one department each week, their safe delivery was essential to protect the company’s reputation. Could polystyrene be the answer for their product packaging?

range cooker product packaging
profiled packaging


  • Polystyrene is durable enough to withstand the weight of the range cookers
  • Polystyrene sheets keep their shape and performance even when being stacked = less storage space needed
  • Bespoke cut polystyrene sheets improve packing efficiency therefore quicker
  • Molygran provides exceptional service from technical helps to site visits
  • Molygran have extremely quick turnaround times also enabling packaging stock level reductions with more frequent deliveries
  • Molygran are able to accommodate all shapes and sizes of polystyrene packaging required

The brief The brief

Imagine 80kg+ range cookers being stacked on top of one another with just a layer of cardboard between them. Would the cardboard carry that weight for a significant amount of time? For Glen Dimplex the knock-on effects of any resulting damage were extensive. Customers returned the cookers wanting a replacement and all damaged cookers had to be re-sold usually at 30% discount, worth around £1250 per unit.

New packaging solutions were sought through competitor analysis, discussions and trials. One option was a ‘honeycomb’ cardboard which was successful, however also very expensive. A metal solution was also far too costly. Their choice of packaging material had to be robust but relatively cheap as it was a throw-away commodity.

The solution The solution

Polystyrene was the obvious material of choice but the correct size, thickness and density were required to provide adequate support. Experts in polystyrene, Molygran suggested correct densities of EPS to use and provided samples of polystyrene sheets in varying sizes to meet the company’s requirements. Soon a solution was agreed on which allowed the product packaging to move into production extremely quickly.

It proved to be the perfect solution. Polystyrene retains its strength and flexibility under pressure which enabled the company to safely stack the cookers as many as six high. Returns have decreased and packaging time has been cut as previously the cardboard needed manipulating into place which increased the labour time.

“Molygran are a reliable and supportive supplier. From providing support at the initial stages with expert polystyrene advice, through to providing samples to find the perfect solution, they have provided fantastic service as can be seen with the length of the business relationship. Our product packaging is now providing the correct support required during transit.”

Geno Smith - Senior Buyer