Case Study: Pioneering Fiber Product Manufacturing to Supply a Global QSR in the Middle East

A supplier to a leading global Quick Service Restaurant (QSR) client, sought to localise the production of moulded fibre products in the Middle East to enhance sustainability and reduce logistical complexities. The client, having no prior experience in moulded fiber manufacturing, required a comprehensive solution to establish a high-volume manufacturing facility from scratch.

W2 Innovations stepped in to spearhead the project from ideation to execution. Our approach involved:

1. Product and Equipment Identification: Through our in-depth industry knowledge and technical expertise, we identified and recommended the most suitable product lines and ancillary equipment to meet the high volume requirements of the client.
2. Design and Development of New Products: We designed innovative cup carrier trays that not only improved product finish but also enhanced performance. The design also took into account the quality of fibre being used, as we designed the facility to be vertically integrated with the client's existing paper packaging business. Allowing the moulding machines to utilise internally generated post industrial waste. Our design team developed initial product samples, which were promptly submitted for testing and approval to meet the global QSR’s stringent standards.
3. Facility Layout and Machine Customization: Once the products were approved, we meticulously selected and customized machines that were aligned with the product requirements. A detailed facility layout was prepared and communicated to the client to ensure seamless integration.
4. Installation and Operationalization: The machines were installed and became operational within the stipulated timeline set by the client. We ensured that every aspect of the setup was calibrated to deliver optimal performance from the get-go.

The new facility allowed the client to completely transition their supply chain from North America and Europe to the Middle East, achieving 100% localization of supply. This strategic move significantly reduced the carbon footprint associated with long-distance logistics and supported regional economic growth. Moreover, the client achieved an impressive 80+% Add Value from this facility, highlighting the efficiency and economic benefits of local manufacturing.

Within just 18 months of commencement, the overwhelming success of the initial production line led to the installation of a second line to accommodate growing local demand. 

This project exemplifies W2 Innovations’ ability to deliver turnkey solutions in complex, high-stakes environments. Our tailored approach and relentless pursuit of excellence ensure that our clients not only meet their immediate goals but are also positioned for long-term success.