R.R. Donnelley & Sons Company helped Levain Bakery™ meet a 200% increase in e-commerce demand during the pandemic.
To address these challenges, the company collaborated with RRD. Available in packages of 4, 8, or 12, Levain's cookies were already packaged in simple, shippable, self-erecting corrugated boxes filled with packing material. Not only were the boxes in need of a redesign to better reflect the brand inside and out, Levain strived to improve product protection and operational efficiency of the packaging. Collaborating closely with Levain's marketing team and designers at The Creative Pack, RRD worked across multiple plants to deliver a vibrant e-commerce box that represents a combination of flexo and litho-lamination techniques. To address product protection, RRD designed a lightweight paperboard insert to accommodate all three pack sizes. The universal insert and redesigned package ultimately cut an 8-step process down to 4 steps. RRD also helped Levain solve its warehousing challenge using a replenishment model. This enabled Levain to receive partial orders for its rolling shipments of 15-pallets per week at its production facility while the balance remained in close proximity at an RRD warehousing facility in Pennsylvania.