TS Food Packaging offers packaging and manufacturing solutions for popcorn and snack foods, serving everyone from emerging start-ups to global brands. What truly sets TS apart, however, is its partnership-driven approach. Passionate about helping its partners succeed, TS Food Packaging shares PCA’s mission, values and commitment to delivering the right solution for every application. That shared mindset has made TS a trusted PCA customer for the past years.
PCA supplies a wide range of corrugated packaging for TS Food Packaging, including a four-piece kit used in club stores. The kit consists of a primary display tray, an insert, a layer pad for interlayer support, and a top cap. Historically, PCA supplied all four components, but the introduction of automated equipment into TS Packaging’s operations shifted part of the four-piece kit business to another supplier, leaving PCA responsible only for the layer pad and top cap. And while the new automation improved efficiency, it also created new challenges, such as additional production line touchpoints and the need for increased support during storage.
Eric Krablean, PCA’s sales representative for TS Packaging, believes strong customer relationships are built on a deep understanding of each customer’s needs. “At PCA, we have a customer-first mindset, so I’m always looking for ways to improve the overall experience,” he said. That mindset led to an unexpected moment of inspiration outside the workplace. “I was out shopping one day when I noticed a box insert and was inspired by its design for TS Food Packaging,” Krablean explained. “I brainstormed with our design team at our Burlington, Wisconsin, plant to explore how we might develop something similar that could fit TS Packaging’s unique application.”
Working collaboratively, the team designed and tested a new single-piece corrugated insert to replace separate components. The new design would have several advantages, including easier setup, while providing more support for handling and warehousing. Krablean took the new design to TS Packaging. TS Packaging immediately saw the benefits and asked for samples to validate efficiency and effectiveness. After doing a test run in their operations, TS Packaging confirmed that the new insert not only worked well for their application, but simplified things.
By leveraging PCA’s design expertise, the team transformed a simple observation into a high-impact packaging solution. The redesigned single-piece insert ships flat and assembles quickly into a strong, supportive structure, reducing handling and simplifying setup on the production line. This collaborative, design-led approach improved operational efficiency while delivering measurable results: nearly one million square feet of material eliminated annually, $123,000 in cost savings, and fewer SKUs to store and replenish.
As Derek Fox of TS Food Packaging shared, “Exceptional care from start to finish! Eric and Stacey’s knowledge, efficiency, and positive attitudes make them a joy to work with.”
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