Case Study: Textile Company's Journey to 100% Paper Core Usage and Its Impact

The case study demonstrates Threadline Textiles' complete conversion to paper core packaging, which produced positive outcomes for their operations, environmental goals, and financial performance.

High-volume operations in material-sensitive industries depend on proper packaging and handling solutions to maintain both product quality and operational efficiency. The textile company, "Threadline Textiles," faced increasing demands to decrease expenses while enhancing sustainability and optimizing its winding and shipping operations. The solution? Transitioning entirely to paper cores.

The paper examines how Threadline adopted 100% paper cores throughout their operations after switching from mixed core systems, and the substantial changes this brought to their business operations, environmental performance, and financial success.

 

The Challenge: Inconsistent Core Quality and Sustainability Demands

Threadline operated across multiple product lines: cotton yarns, synthetic fabrics, and blended materials. The company previously used plastic cores in conjunction with paper cores, based on product weight specifications and durability requirements. However, this mix introduced multiple challenges:

•  Inconsistent winding performance: Plastic cores were reused but often damaged, leading to unwinding issues during production.

•  High material costs: Plastic cores were more expensive to procure and harder to replace quickly.

•   Environmental concerns: Pressure from retail partners and end-users pushed the company to adopt more eco-friendly practices, especially in packaging and logistics.

The company required a solution that combined reliability with strength and environmental advantages while maintaining operational performance.

 

The Shift: Partnering with Erdie Industries

The operations team at Threadline initiated contact with Erdie Industries to develop specialized high-strength paper core solutions. The initial phase involved:

•   A comprehensive evaluation of product weights along with winding speeds and transport needs from all product lines.

•   The engineers at Erdie created specialized paper core products with adaptable thicknesses and diameters to support the mechanical operations of various looms and winding machines.

•   The paper cores underwent testing at high-speed production speeds to verify their dimensional stability and crush resistance capabilities.

Erdie Industries demonstrated precision manufacturing capabilities of bulk recyclable cores with consistent performance, which led Threadline to start their phased paper core implementation.

 

The Results: Operational and Environmental Wins

Threadline achieved substantial enhancements in operational efficiency and environmental impact during its six-month transition to paper cores.

1. Operational Efficiency

•   The precise dimensions of Erdie's paper cores led to a 12% decrease in machine stoppages that resulted from core-related problems.

•  The elimination of plastic cores made the procurement process simpler while simplifying inventory management operations.

•   The paper core weight made them easier for workers to move and position, which enhanced factory floor operational efficiency.

 

2. Cost Savings

•   Lower material costs: On average, switching to paper cores cuts packaging core costs by 30%.

•    Fewer product returns: Improved core quality reduced fabric damage during winding and shipping, lowering returns and waste.

 

3. Environmental Impact

•   Zero-waste core policy: All paper cores were made from recycled content and recycled again after use, aligning with Threadline's sustainability goals.

•   Improved brand perception: Retail clients and eco-conscious buyers responded positively to the switch, opening new B2B opportunities.

 

Lessons Learned

Threadline's transition to using 100% paper cores exposed several essential business lessons to the company.

•  Strength and sustainability can go hand in hand. The custom solutions developed by Erdie proved that paper cores maintain durability beyond expectations.

•  Customization is key. The customization of cores to fit Threadline's production specifications enabled them to maintain performance levels.

•  Supplier partnerships matter. The close collaboration between Threadline and Erdie enabled a seamless transition and ongoing optimization efforts.

At Erdie Industries, we take pride in helping companies achieve operational excellence while protecting the environment through our paper core manufacturing services.