Custom Corrugated Display Solution for Baseball Cap Retail
This customer case study features a client from the UK that operates a retail chain specializing in branded baseball caps. Although it is a chain, since the stores were opened gradually, many of the older locations still use standard metal display racks—which are bulky, difficult to move, and not well-suited for promotional activities. Therefore, the client was seeking display racks that are flexible, lightweight, and easy to use for promotional campaigns. Below, Topwon shares details about the baseball cap paper display rack project:
March 2024: The Need Arises
A manager from a UK-based branded baseball cap retailer sent us an inquiry. The gist of their message was as follows: With over 20 stores nationwide, many of the older locations—having opened gradually over time—still use metal shelving units that were popular years ago. While these units are of very good quality, they come with high installation costs, are difficult to move, and are not well-suited for promotional displays. Overall, they feel rather rigid and do not align with the style of the baseball cap brands they currently sell. Additionally, the caps hung on metal hooks appeared disorganized and crooked, creating a poor visual impression and failing to highlight their flagship products, resulting in a subpar customer experience. They sought custom display racks that aligned with their brand’s aesthetic, allowed for targeted promotions of key products as needed, and enabled the neat and orderly arrangement of regular merchandise to create a clean, sophisticated look. The display racks themselves must also be visually appealing, complementing the brand’s aesthetic, and feature the company’s logo and promotional brochures. To facilitate seasonal promotions, the racks may need to be replaced periodically. Therefore, they must be easy to install, flexible to customize, and cost-effective.
April 2024: Preliminary Proposal Implemented
Based on the client’s specific requirements, Topwon’s design team conducted a thorough analysis and proposed a preliminary solution using Type E corrugated cardboard as the main material.
1. Material: Corrugated Cardboard
Aligns with international environmental standards and is cost-effective. To meet overall load-bearing requirements, we adopted
2. Customized Design
The customized design not only aligns with the client’s brand style but also meets the specific promotional needs of the current sales season.
3. Adjustable Hook Positions
12 adjustable hook positions accommodate not only new baseball caps but also adapt to different styles such as bucket hats and snapbacks.
4. Folded Shipping and Quick Assembly
Pre-creased for tool-free assembly, the display ships fully folded to reduce logistics costs. The quick-install design allows a single display to be set up in minutes without tools, accompanied by an installation video and online guidance.
After extensive communication, the client was satisfied with the overall solution but requested some refinements, such as:
5. A large brand logo banner at the top
6. Added storage compartments to facilitate restocking of high-selling styles by store staff
May 2024: Store Launch
The first batch of display stands was delivered to several stores in the UK. Thanks to the tool-free installation design, the stands were set up with ease. The customer reported, “It’s so exciting—the installation was even faster than I imagined.” Take a look at the installation video Wendy filmed herself; it’s practically magic. The style of the display stands complements our baseball caps, brand, and logo perfectly.
In summary, the first batch of paper display stands for this baseball cap brand’s chain stores has been successfully installed. According to customer feedback, on-site promotional activities are proceeding smoothly, and sales have seen a noticeable increase—though the exact figures weren’t disclosed, likely due to commercial confidentiality. We look forward to continuing our collaboration and gradually replacing the display stands in other stores. This experience gives us even more confidence in customizing and replacing displays for future large-scale seasonal promotions.
Please note ：due to client confidentiality, the images in this article do not depict the actual display racks or products of this customer.
