Private-Label Clutch Kit Programme for a Spanish Parts Brand
Client
A motorcycle parts brand in Valencia, Spain
Industry
Private Label / Brand Owner
Key Impact Metrics
The Challenge
The brand had a clear plan: a clutch kit is a repair decision, and a rider buys the whole set at once. Selling friction plates, steel plates and springs separately — which is how most of the market still does it — leaves money on the table.
What blocked them was order size. Their previous supplier quoted 1,500 pieces per reference and 90 days, which for nine SKUs would have meant tying up most of a year's working capital in a single product line.
They also could not sell into retail chains with plain poly bags. The chains wanted a barcoded box with a window or a clear photograph, multi-language text, and a consistent shelf footprint.
Our Solution
We started from the packaging instead of the parts, because the packaging is what sets the minimum order.
- One box, nine labels: a single carton size with a printed label panel carries all nine references. Only the label changes between SKUs, so the print run is shared and the per-SKU minimum drops to 300.
- Contents: friction plates, steel plates, springs, and the cover gasket in one box, with a foam insert so the plates cannot rub against each other in transit.
- Compliance: EAN-13 barcode, batch number, and a QR code that resolves to the fitment page for that reference.
- Languages: Spanish, French and Portuguese on the label panel, matching the three markets the brand sells into.
First production ran in four weeks, including two artwork revisions.
The Result
All nine references were listed by a Spanish national chain within the first quarter, and the brand placed a repeat order six weeks after the first delivery — earlier than their own sell-through forecast.
The shared-carton model also made it cheap to extend the line. Brake pads were added later on the same label-panel system, and the brand has since moved two more categories onto it.
Why the minimum order is a packaging problem
When a supplier quotes 1,500 pieces per reference, the number is usually driven by the printed carton, not by the parts. Tooling for a custom box, a dedicated print run and a specific insert each carry a fixed cost, and that cost has to be spread over a batch.
Standardising the carton and moving product differentiation onto a label panel breaks that link. The box becomes a shared component, the print run covers every reference at once, and the minimum order can drop to something a mid-sized brand can actually finance.
What has to stay custom
Not everything can be standardised. The foam insert has to match plate diameter and stack height, otherwise the contents move in transit and the customer opens a box of scratched steel plates. We keep three insert sizes that between them cover the common 125cc to 250cc fitments.
The label panel carries the fitment list, the batch number and the QR code, so it has to be printed per reference and per batch. That is a small-format digital print job, which is why it does not force a large minimum.
Assembling in-house vs buying assembled
Kitting is labour. For nine references at 300 pieces, we assemble to order rather than holding assembled stock, which keeps the customer's capital freed until the order is confirmed. Above roughly 2,000 pieces per reference it becomes cheaper to hold pre-assembled stock and shorten the lead time instead.
Project Highlights
- Agile development methodology
- Dedicated project manager
- 24/7 support & maintenance
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