Case Study

Replacing Plastic With Sustainable Corrugate

The Opportunity

A client needed a durable display to hold heavy demo product. Their existing design relied on a large plastic wedge for structural support, an expensive and unsustainable solution.

The Solution

Bay Cities’ structural design team re-engineered the display using corrugated as the primary material. To maintain strength and stability, we incorporated minimal hardware: a couple of small plastic backer plates, screws, and zip ties – eliminating the need for the bulky plastic wedge. To achieve a solid black graphic background with reverse print, we decided to use flexography for the printing, which is the most sustainable printing method.

The Result

The redesigned display matched the same graphic expectation and delivered the same structural integrity at a lower cost while significantly reducing plastic use. This creative solution not only saved the client money but also prevented unnecessary plastic waste from entering landfills, demonstrating Bay Cities’ commitment to sustainability through smart design.

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