Alexir Creative adds new Zünd cutter to meet future growth plans

The move forms part of Alexir’s wider strategy to continue to offer its broad range of services range of services it offers and reinforce its position as a fully integrated packaging and co-packing partner for the FMCG sector. Alexir designs and manufactures bespoke folding carton packaging and stands out in the UK market by guiding customers from initial concept through to finished product packing, all within a single partnership.

Over the last ten years, the design capabilities at Alexir Creative have grown significantly. With a larger sales team bringing new projects into the business, demand for structural design, prototype development and printed samples has increased. The studio now has four designers working across multiple projects, including constructional packaging design and product development. A product developer within the team also uses the cutting tables to produce printed samples and white prototypes for testing and presentation. As a result, the existing equipment was operating at full capacity, creating a bottleneck. Claire Summersby, Head of the Creative Packaging Studio at Alexir Creative said "Over the past decade we have seen strong growth in demand for structural packaging design and prototyping. Our customers increasingly want to see physical samples quickly to keep projects moving. With four designers using one cutting table, we began to hit capacity limits. The additional Zünd cutter was required to gives us the space we need to support both our current workload and the growth we are planning over the next five years."

Choosing Zünd for the additional cutter was a straightforward decision. Jason Gardiner, Senior CAD Designer at Alexir Creative said "As a long-term user of Zünd cutting technology, the studio has built a strong relationship with the Swiss brand and we have consistently experienced reliable performance from our existing cutter. The outstanding service and technical support we have received over the years also played a key role. Having a partner that understands the demands of a busy design studio and responds quickly when needed gives us confidence that our investment will continue to perform as the business grows."

The investment was accompanied by a physical expansion of the creative studio. The team extended into adjacent warehouse space to accommodate the additional equipment and new workflows. The Zünd cutter allows the studio to produce multiple prototypes simultaneously, including white samples and printed mock-ups that help customers visualise packaging concepts before full production. Unlike many traditional carton converters, which often produce only basic prototypes, Alexir Creative operates as a fully equipped design studio capable of producing a wide range of packaging samples in house. Claire added "Our goal has always been to create a studio where customers can develop their packaging without needing to go elsewhere. We can produce white samples and printed mock-ups as part of the development process. That level of capability helps brands test ideas quickly and move projects forward with confidence."

The investment reflects the broader approach of Alexir Partnership Group, which has spent the past decade expanding capabilities across design, carton manufacturing, dried food co-packing and global sourcing. This integrated model allows brands to develop packaging concepts, produce prototypes, manufacture cartons, and pack finished products within a single supply chain. Alexir works with a wide range of well-known brands and retailers, including airlines such as British Airways and Emirates, as well as retailers including Tesco and Sainsbury’s.

Claire said “One of our key strategies has always been to expand the services we offer our customers. Packaging design and rapid prototyping play a huge role in bringing new products to market. Being able to create concepts, build prototypes, manufacture packaging and pack the finished product all within one partnership gives our customers real efficiency and reliability."

Fiercely independent for more than 35 years, Alexir became employee-owned in 2019, with every team member invested in the long-term success of the business.

The latest investment in the Alexir Creative studio ensures the team has the tools and capacity to continue supporting customer innovation while meeting the company’s ambitious growth plans in the years ahead.