How We Make Packaging for Shipping Posters
The other day we went to pick up foam cylinders. Anyone who has already received our prints knows exactly what I'm talking about. This is a story about how we faced challenges more suited to designing an aircraft — even though it's just a postal box.
The story of these cylinders began in 2019 with one failed delivery. Back then, we were shipping our prints simply rolled up inside a homemade cardboard box with a triangular cross-section. We chose that shape specifically to protect the roll from being crushed — everyone knows that a triangle is a sturdier structure than a rectangle. The only protection for the print was bubble wrap, but it couldn't shield the photo paper from deformation caused by the collapsing sides of the outer cardboard box. And then came another failed delivery — the customer received a crumpled poster. Sadly, this was not uncommon. The box showed no obvious external damage, but the poster inside was deformed. After studying the nature of the damage, we concluded that the poster had been crushed due to the stress loads that occur during transportation.
Unfortunately, it's not unusual these days for baggage handlers to show little regard for the contents of aircraft cargo holds. All sorts of short videos circulate online showing parcels being "expertly" launched into imaginary basketball hoops or football goals — and thankfully no one has thought to use baseball bats yet. Although, I probably shouldn't have said that — don't give the handlers any ideas!
And even though that particular customer didn't file a complaint, it was precisely then that we decided enough was enough — it was time to do something about the problem. We needed to come up with additional protection for the roll that would prevent it from being crushed.
The challenge was made harder by the fact that we were trying to keep shipping costs to a minimum, and the price depended on the weight of the parcel. Up to that point we had been staying within the "up to 250 grams" bracket, and any increase in packaging weight would push us over that threshold — effectively doubling the shipping cost. We tried a huge number of options, and every one of them meant we'd have to raise our prices due to the higher postage.
Then, just when we had almost given up hope, the solution appeared! While searching for a cylindrical core for the poster — a task my wife had taken on — she found the most optimal option: foam cylinders cut to our specifications on request. After contacting the manufacturer, she visited the facility and brought back several samples of different diameters and densities. After testing them in practice, we settled on the ideal size and placed our first order. And the most magical thing of all — the cylinder was so light that we had every chance of staying within our existing postage rate.
At the same time, I redesigned the cardboard box so that it could fit the cylinder with a maximum of six posters wound around it, all wrapped in a single layer of bubble wrap. The first version of the packaging hit the target parameters almost to the gram. But then a new snag appeared: after sticking on all the required postal addresses, customs declarations, and stamps, the total weight exceeded 250 grams by a few grams. So we continued refining things — we reduced the length of both the cylinder and the tube by about five millimetres, and trimmed the width of the flaps on both end caps. Problem solved!
Since then, our tube has worked flawlessly. Over time we found another material for the cylinders, which freed up a few more grams. And the postal service updated its parcel documentation, so there are now far fewer stickers and forms to attach. Since then, we've had no further issues with posters being deformed from box compression.
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What is there to read?
A Short Note
I don't always have the time, energy, or skill to write long analytical articles with a cleverly crafted narrative. I'm more of an artist than a writer, after all. But often the subject I'm working on is so captivating that I feel an irresistible urge to share more than what fits on the poster. When researching the history of an airline, you start to understand the transformations it has gone through, and events sometimes reveal themselves from quite unexpected angles.
The two short stories published in the February blog appealed to me because unexpected — even seemingly illogical — events turned out to have roots stretching far back into the past.
An Unexpected Return
How did Singapore Airlines — known for its long-haul routes and a fleet made up exclusively of wide-body heavyweights — end up with a narrow-body Boeing 737-8 MAX? In any other context, this aircraft is positioned as a plane for medium-range routes. But among giants, it plays the role of a regional jet. And yet, this very airline once started out with the 737.
India's Premium Airline
In India, nothing disappears without a trace — everything is reborn in a new form. The country's first premium carrier is no exception. It no longer exists today, yet all of its aircraft are still in service, flying across the country and around the world. How is that possible, and how did Vistara end up as Air India's closest relative?
Read all about it on our blog.
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New Additions to the Catalog
New Works
February turned out to be generous — not just with snow and blizzards. New posters have appeared in our catalogue, most of which have already made their way to their new homes. These included both brand-new works and updates to existing posters.
Among the new additions to the project are two classic Boeing 737s — the Russian low-cost carrier Sky Express with its vivid, colourful livery, and another low-cost carrier, Helios, from the shores of Cyprus. Both operators have long since ceased to exist, but for those who flew on these aircraft, our poster is a page from their life.
The updates feature three aircraft. The British "Jumbo" — a veteran of the skies, once ruling the heavens; its place has now been taken by other giants. And two more... or one... or, actually, two. Two posters, two operators — but the same aircraft! Yes, that happens too.
Next up are already more posters, some of which are ready and will be published any day now. Details in the news on the Gallery page.
Full details on the "Poster Gallery" page.
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1. The British Jumbo
British Airways was once the world's largest operator of the Boeing 747-400, with a fleet of 57 aircraft. The "Queen of the Skies" served as the backbone of the airline's long-haul operations for over 30 years. But the COVID-19 pandemic in 2020 forced the airline to retire its entire Jumbo fleet. The aircraft featured on our poster, G-CIVG, had already left the British fleet as part of a planned fleet renewal back in 2019 — four months before the mass retirement.
This poster first appeared on our website back in 2017. The current update marks its revival after nearly four years of absence.
2. Sky Express — Russia's First Low-Cost Carrier
The first fully-fledged low-cost carrier in Russia was Sky Express, founded in 2006. Its inaugural flight on the Moscow–Sochi route was operated by a Boeing 737-300 registered VP-BBN — yes, the very same aircraft depicted on our poster.
Interestingly, the original order that came in was for a poster of this airline, but with the registration N527AD. That's the same aircraft, but before it received its permanent Russian registration — N527AD being the seller's temporary registration. I completed the order and sent the drawing as requested, but decided to add the aircraft to the catalogue under its VP-BBN number. Incidentally, it wasn't just the tail number that needed changing — all the technical stickers and markings had to be updated too, as they differed significantly from the original version.
The version with the American registration is still in my files, so feel free to get in touch if you'd like this rare variant. N527AD is of particular interest to scale modellers, as a model of this aircraft was produced by the modelling industry. The main reason for the popularity of this registration is the Eastern Express 1:144 scale kit, whose decal sheet maker chose to include markings with the US registration. This version gained even wider circulation in the collector community thanks to JC Wings, which released a highly detailed 1:200 scale model specifically under the N527AD registration.
3. Helios Airways — Not the Luckiest Start-Up from Cyprus
I should say upfront — this is not the aircraft that became tragically famous! Our poster is dedicated to the very first aircraft in the Helios Airways fleet, which flew with the company for about a year before moving on. For someone, this particular aircraft was something special — special enough to order a poster of it as a keepsake. Was it the aircraft on which they took their first flight as a pilot? Or perhaps the one on which they first took to the skies as a passenger? Who among us doesn't remember their first encounter with the sky? Either way, these are warm memories — and I help preserve them for years to come.
4 & 5. One Aircraft, Two Lives
These two posters are inseparable, because they depict the same aircraft — just at different points in its life.
From its very first days, it flew in the livery of German cargo carrier Lufthansa Cargo. In those years it was beloved by spotters and aviation enthusiasts alike, and its registration D-ALCN was known by heart. Whenever the aircraft came into view of those in the know, there was a stir in the crowd — enormous lenses swung skyward, and an excited "It's him!" swept through the gathering. And no wonder, for this aircraft was the last MD-11 ever built, marking the end of an era of legendary giants. In 2018, it took its place on one of our posters.
When the COVID-19 pandemic struck in 2020, Lufthansa began hastily disposing of its ageing MD-11 fleet. D-ALCN passed to American carrier UPS and in April of that year received its current registration, N262UP. By the end of the same year, a new poster appeared showing the MD-11 in its new guise.
Following a tragic incident last year, UPS retired its entire MD-11 fleet, including the 262nd. Whether it will ever fly again remains to be seen. In the meantime, we have preserved it for lasting memory in our posters, which I recently updated.