Grant: Applied Research and Development Grants - Level 1

Willow Box Manufacturing Ltd (Willow Box) is a Canadian company, located in Berwick, NS. The company has been producing quart and pint wooden basket from softwood logs for more than ten years. These boxes are sold to strawberry growers throughout Nova Scotia, New Brunswick and Prince Edward Island, with increasing demand from Quebec and Ontario. The manufacture of these boxes remains a labor-intensive process; growth and competitiveness of the product bears important risks around ability to retain and grow skilled workforce, or alternatively invest in automation and technology. The availability of other materials to make similar baskets has developed following the extensive use of plastics in the past decades, which has challenged more sustainable wood-based products. However, the recent plastic global concerns have increased demand on sustainable solutions while fulfilling the market needs of consumables. The company therefore plans to expand its facility to acquire the increase production capacity required to fully meet the increasing market demand, and now seeks Nova Scotia Community College's (NSCC) applied research support to stimulate a custom process innovation based on a lean approach. The recent disruption in supply chain due to the COVID-19 pandemic has generated growing market demand for close-proximity sustainable and reliable supply. NSCC's Engineered Technologies Applied Research group specializes in product development and process optimization. This research project will advance product design and manufacturing techniques and technologies to enable Willow Box and other similar companies to enhance process flow and productivity to scale to meet market demand. Advanced production techniques such as those in this study result in economic benefits for both the company and the modernization and competitiveness of this Canadian market sector. Knowledge translation from the project will benefit other companies in the sector, with the goal to elevate overall quality and productivity in the region, directed to export.