Author: Niki Blane

We all strive for speed to market – faster launches means getting products onto shelves before the opportunity passes.

So it’s understandable that any ‘extra steps’ in the process feel like they would slow things down. But there is an exception, (especially where Alexir is involved) – and that’s white samples.

 

What are white samples?

 

White samples are physical, 3D prototypes of your packaging, before print is applied. They typically have no branding, no colour, but the structure, format and feel that gives you a tangible product to test. It’s the moment where an idea stops being theoretical and becomes something you can actually hold and assess.

With a white sample you can see how it opens, how it holds the product, whether it feels right in the hand and whether it does the job it’s meant to do on shelf. These are things that drawings and PDFs simply can’t answer properly.

 

Why do white samples matter for speed to market?

With white samples, any necessary changes are caught early on in the process, removing delays later on.

Once you move into full production, changes can become much more costly and halting production can cause severe delay. Carton manufacturing alone can take six to eight weeks after artwork is approved, so if something isn’t quite right at that stage, you’re not making small tweaks, you’re starting again.

White samples allow you to spot issues early, align stakeholders quickly and make decisions with confidence. The faster you can get white samples in front of people, the faster the entire process moves forward, eliminating potential production delays.

 

How can Alexir produce white samples so quickly?

The issue with white samples is that for many brands, sampling isn’t as straightforward as it should be. Design might sit with one agency, print with another supplier, and manufacturing somewhere else entirely. Each step introduces another handover, another interpretation and more time.

So sometimes what should be a quick validation step can easily become a bottleneck. But this is where Alexir approaches things differently.

White sampling isn’t treated as a separate stage – it’s part of our connected in-house creative and manufacturing process, which removes a lot of the usual friction.

Typically, white samples can be turned around in 48 – 72 hours from the point of request (with exceptions for extremely complex designs). That kind of speed makes a real difference, particularly when decisions need to be made quickly. It also means teams aren’t waiting around to move forward. They can review, refine and progress without losing momentum.

 

What is the Zünd cutter?

A big part of that speed comes from our new Zünd cutter, which is an investment we’ve made to allow us to move from concept to physical sample almost immediately, without the need for traditional tooling. 

The samples produced aren’t rough approximations, they’re structurally accurate, giving a clear representation of how the final pack will behave.

Combined with in-house print capability, we make things move even faster, with no need to pass files between multiple suppliers or wait for external production. Everything happens in one place.

White sampling at Alexir isn’t limited to cartons. The same approach applies across a range of formats, including rigid boxes, corrugate outers, pouches, sachets and pots. That flexibility is important, especially for brands exploring new formats or testing different ways to present their products.

It gives you the freedom to experiment properly, rather than being constrained by what’s easiest to produce.

 

How do Alexir white samples improve speed to market? 

White samples, (especially Alexir Partnership white samples), can have a direct impact on how your products get to market. Here’s how we make a difference:

• Immediate physical prototypes, not just concepts

White samples allow brands to hold, assess and sign off real packaging formats early, speeding up decision-making from the outset.

• Rapid iteration using in-house cutting technology

With tools like the Zünd cutter, Alexir can produce multiple format variations quickly. That means ideas can be tested, refined and approved in days rather than weeks.

• Early-stage problem solving before production

Structural, material and packing challenges are identified and resolved during the white sample phase. Fewer surprises later means fewer delays when moving into full production.

• Seamless transition from sample to manufacture

Because design, sampling and production sit under one roof, what’s approved as a white sample is already aligned to real manufacturing capability, with no handover friction.

• Faster customer and retailer sign-off

Physical samples make it easier for stakeholders to visualise the final product. Speeding up internal approvals and retailer acceptance gets products onto shelves sooner.

 

When speed matters, start here

For launches where timing matters, whether that’s seasonal products, retail opportunities or new product development, speed matters. White samples are just one part of the process, but they have a disproportionate impact on how everything else flows.

When they sit within a connected system that includes design, print, co-packing and delivery, the entire journey becomes more efficient. That’s where Alexir, with full creative and production capability in-house, is strongest. 

If reducing time to market is a priority, get in touch to find out more. 

 

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Anyone who works in FMCG, knows that the journey from idea to shelf can be complex. Bringing a product to market involves dozens of decisions, multiple components and a production process that has to be carefully engineered around each individual product.

 

Most brands who come to Alexir Co-packing fall into two camps:
– They either have huge fixed production lines that are too complex and expensive to halt or change for NPD, or
– They have no manufacturing capabilities at all, but great ideas they want to bring to market ahead of their competitors

 

Both need a partner who can confidently own the whole supply chain. Customers often come to us not knowing if something is possible, or thinking it might be too complicated, but this is where the Alexir Co-packing team comes into force. With our can-do approach and incredible flexibility afforded by our extensive range of production equipment we can create endless production line configurations, rapidly.

 

A fast way to test and deliver new product formats

Alexir Co-packing turns concepts into fully assembled retail products. The process combines engineering, logistics, testing and production planning to ensure every product is packed efficiently, safely and ready for market.

 

Most projects start when a customer approaches Alexir with an idea – either a completely new product, or a new format for an existing product.

 

A typical example is when a manufacturer produces a single product on a highly automated production line, but wants to sell it in a different retail format. Instead of redesigning their own factory lines, they can work with Alexir to create the new configuration.

 

For example, a manufacturer producing single packs may want to launch a value four-pack for retail. The individual products are delivered to Alexir, where the co-packing team designs a production line to assemble and package the new format. The production line is tested to ensure quality and speed of production and once approved, can be used to introduce new formats without investing in expensive new manufacturing lines.

 

Building bespoke production lines to deliver new product formats

One of the most important parts of the process is designing the production line itself.

 

Unlike highly automated factories that produce one product repeatedly, Alexir can build a bespoke production setup for each project. This flexibility allows us to offer thousands of combinations to deliver unique products.

 

As Dom Wing, Operations Director for co-packing, explains:

“Every production line is different. Customers want different things, so we configure the machines and the process around the product.”

 

A typical production setup may include multiple machines working together, such as:

• Feeding systems
• Weighing or dosing equipment
• Pouch machines
• Coding and labelling systems
• Metal detectors
• Cartoning and packing machinery

 

These machines are combined in different ways depending on the product.

 

In some cases, the process may include blending ingredients, filling sachets and then assembling them into a retail kit. In others, the focus may be on assembling multiple finished components into a single retail pack.

 

This modular approach allows Alexir to create production lines that are tailored to each product.

 

Trials and testing the production lines 

Before full production begins, the team runs trials.

 

These trials test:

• How ingredients flow through machines
• Whether packaging materials work effectively
• The speed the line can run at
• The final appearance of the finished product

 

Sometimes this happens under tight deadlines, especially when brands are racing to launch new products.

 

During trials, the team works closely with Alexir’s Packaging and Creative teams. Sample cartons or packaging formats may be tested on the line to ensure they are practical to pack and robust enough for retail distribution.

 

If something doesn’t work, it’s redesigned before production begins.

 

Managing multiple co-packing projects at once

Co-packing operations often run several production lines simultaneously.

 

At Alexir, the facility can run up to seven food production lines at the same time, depending on the resources required for each project.

 

Each line requires careful coordination between:

• Engineering teams setting up machinery
• Production managers running the lines
• Warehouse teams preparing stock and materials
• Quality teams ensuring compliance

 

Behind the scenes, the operations team plans all of this in advance to ensure materials, people and equipment are ready when production begins.

 

Scaling production up or down

Flexibility is one of the biggest advantages of co-packing.

 

While some processes are automated, others involve manual assembly. This is intentional.

 

Automating every process only makes sense when producing extremely large volumes. For many projects, particularly seasonal or limited-run products, manual elements make production more efficient and cost effective.

 

We maintain a core team while working with partner agencies to scale staffing levels up or down depending on production demand.

 

This allows us to respond quickly to customer requirements.

 

Ensuring safety and quality

Despite so many moving parts, food safety remains critical. Production areas are carefully controlled to prevent contamination and manage allergens. Different rooms are used for different types of products, and lines are separated where necessary to maintain compliance with food safety standards.

 

Cleaning procedures are carried out between runs, and swab testing is used to verify that equipment and production environments are safe before production starts again. 

 

Supporting innovation and speed to market

For many brands, co-packing is a way to test new ideas before investing in expensive manufacturing infrastructure. Instead of building a dedicated production line, our flexible production lines allow brands to launch products quickly and see how they perform in the market.

 

“It’s a way for brands to get to market very quickly without having to invest in a huge amount of capital,” says Dom.

 

If a product becomes a long-term success, brands may eventually bring production in-house. If not, they can continue producing through Alexir without the financial risk of building their own production line.

 

This approach makes co-packing a powerful cost-effective tool for innovation.

 

Turning ideas into retail-ready products

From blending ingredients and filling sachets to assembling kits and packaging finished goods, Alexir Co-packing handles a wide range of production challenges.

 

But our vast arsenal of machinery, experienced operators and integrated support from the wider Alexir Partnership, ensure brands can move from concept to shelf faster and more efficiently.

 

Behind every product is a carefully engineered process designed to make it work.

 

So why use Alexir Co-packing?

To break it down, there are 6 core reasons that brands use Alexir Co-packing, rather than internal production lines or other Co-packing facilities…

 

• Speed to market

New formats and products can be developed and launched far faster than building new manufacturing lines. In some cases, projects move from concept to production in just a few months.

 

• Cost-effective innovation

Instead of investing in expensive equipment, brands can test new products in the market first. If the product succeeds, they can scale up later.

 

• Flexible production

Each project is built around the product using a wide range of machines and processes to create the ideal production process. 

 

• Bespoke formats

From meal kits to value packs, our turnkey Partnership structure and ‘can-do’ attitude allow brands to create new shelf-popping retail formats in one smooth operation. Where there’s a concept, we can create it.

 

• Scalable production

Our factory typically runs 12-hour shifts, with the ability to add night shifts when large orders need to be completed quickly.

 

• True operational agility

With multiple production rooms, experienced engineers and flexible staffing, we can adapt quickly to changing customer needs.

 

 

Want to explore what’s possible?

If you’re looking to bring a new product to market, we’re ready to support you.
With incredible flexibility afforded by near-endless production line configurations, and a ‘can do’ attitude, we can help you to deliver stand-out products to the shelves quickly, without breaking your own production lines or investing in expensive equipment. Get in touch to get started

 

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