Custom Retail Displays Case Studies
Real Projects. Real Rollouts. Built by BAW.
At BAW Plastics, we do more than manufacture displays. We help turn ideas, sketches and concepts into finished retail programs — handling everything from design and prototyping to production, printing, assembly, kitting and fulfillment.
Whether it’s a custom display for a single location or hundreds of fixtures shipping nationwide, we’ve got you.
Explore some of the projects we’ve brought from sketch to store.
Case Studies & Nationwide Rollouts
Best Buy: 800 Store Nationwide Retail Display Rollout
When Best Buy needed a new merchandising solution for its prepaid mobile category, BAW Plastics helped take the program from production through pack-out — ultimately delivering complete display packages for 800 Best Buy stores nationwide.
BAW manufactured the primary black display structure, produced the printed back panels and graphic components, and brought together the additional parts needed for each location. Everything was organized, packed and shipped as a complete store-ready package, allowing the individual stores to add the prepaid phone cards and merchandise during installation.
The Challenge
Executing one display is one thing. Executing it consistently 800 times is another.
Best Buy needed a durable retail fixture capable of merchandising multiple prepaid wireless brands while maintaining a clean, consistent appearance across hundreds of stores.
With numerous components involved, manufacturing was only part of the challenge. Every location needed to receive the correct pieces, properly organized and ready for installation.
The BAW Solution
BAW served as a manufacturing and fulfillment partner for the rollout, coordinating multiple stages of the project under one roof.
We manufactured the black structural display fixture, produced the printed back panels and graphics, coordinated the various components required for each display, and handled assembly, kitting and pack-out.
Each store received the components needed to create the finished prepaid mobile destination shown here. Once in store, Best Buy added the phone cards and final merchandise.
The result?
800 stores received a consistent, ready-to-deploy retail display program.
Large retail rollouts aren’t just about making the fixture.
They’re about making sure Store #1 and Store #800 receive the same quality, the right components and a display that’s ready to go.
That’s where BAW’s combination of manufacturing, printing, assembly, kitting, warehousing and fulfillment makes a difference.
From Sketch to Store — and Everything in Between.
BAW Plastics provides custom retail display manufacturing for regional and nationwide programs, including custom fixture fabrication, plastics, wood and metal capabilities, digital printing, assembly, kitting, pack-out, warehousing and nationwide fulfillment.
Planning your next retail rollout? Reach out on our contact request form:
Nationwide Crossword Spinner Rollout
When a custom merchandising solution was needed for The New York Times Crossword, BAW Plastics was tasked with turning a basic concept into a finished retail display that could be produced at scale and delivered to stores across the country.
The result: a custom rotating floor display designed to merchandise a variety of crossword books in a compact, easy-to-shop footprint.
The Challenge
The project began with a basic sketch and a clear objective: create a custom spinner display that could showcase multiple crossword titles while maintaining a clean, organized presentation on the retail floor.
But designing the fixture was only the beginning.
The display needed to be repeatable, durable and consistent across a large production run, while meeting specific in-store color requirements and being ready for a coordinated nationwide rollout.
The BAW Solution
BAW took the project from concept through production and fulfillment — all managed in-house.
Our team designed and fabricated the custom rotating display, incorporating clear acrylic merchandising pockets, a durable base and branded signage to create a compact fixture with strong product visibility.
BAW also sourced the laminate required to meet the specified in-store color requirements.
Quality at Scale
Large rollouts require consistency.
BAW completed more than 1,700 hours of in-house fabrication while maintaining a less than 0.5% rejection rate during production and a 0% rejection rate in the field.
That’s the kind of quality control that matters when the same fixture is being installed in stores across the country.
BAW didn’t stop when manufacturing was complete.
The rollout was managed entirely in-house, including coordinating and drop-shipping more than 600 pallets so displays could arrive across the country on a coordinated schedule.
From the original sketch through fabrication, quality control, packing and nationwide distribution, BAW managed the project from start to finish.
From Sketch to Store.
For BAW Plastics, this project brought together what we do best:
Custom retail display design
Acrylic fabrication
Wood and laminate fabrication
Prototyping and production
Quality control
Assembly and pack-out
Nationwide drop shipping and fulfillment
Have a retail display idea? We can help. Send us a message on our contact request form.Â
AÂ Smarter Sign Holder Solution for Walgreens
Simpler Design. Lower Costs. Same Great Functionality.
Sometimes, a small design change can make a big difference.
At BAW Plastics, we don’t just manufacture custom retail displays. We look for opportunities to improve them, helping our customers simplify production, reduce costs, and find better solutions.
That’s exactly what happened when our sales representative, Jim Wadding, visited a Walgreens mock store.
The Challenge
While walking through the store, Jim noticed a sign holder constructed from both metal and plastic.
Although functional, the design presented several challenges:
Multiple materials: The sign holder required separate metal and plastic components.
Additional weight: The metal increased the overall weight and shipping costs.
Unnecessary complexity: The design was more complicated and expensive than it needed to be.
Jim recognized an opportunity to create something better.
The BAW Solution: Rethinking the Materials
Rather than simply reproducing the existing sign holder, Jim proposed a redesigned version that eliminated the metal component altogether.
By using plastic and screen printing the silver section to maintain the desired appearance, BAW developed a simpler, lighter, and more economical alternative.
The new design maintained the intended functionality and appearance while eliminating unnecessary material and weight.
Walgreens ultimately selected BAW’s redesigned sign holder over the original option.
The Results: Less Can Be More
The redesigned sign holder delivered several important benefits:
Reduced material costs: Eliminating the metal component helped create a more economical product.
Lower shipping costs: A lighter design meant less weight to transport.
Simplified construction: Fewer materials and components made the product less complicated.
Our team works closely with customers to evaluate materials, explore design alternatives, develop prototypes, and manufacture products that meet their needs and budgets.
From custom retail displays and signage to OEM components and specialty fabrication, we’re always looking for ways to make things better.
Facing rising material costs or lengthy lead times?
Before committing to an expensive or complicated design, let BAW take a look. A different material or a small design adjustment might make all the difference.
Let’s find a smarter solution for your next project:
Small Part. Big Impact for Kohl’s.
How BAW Plastics Turned a Simple Yellow Component into a Nationwide Solution for Kohl’s
Sometimes, the smallest projects make the biggest difference.
At BAW Plastics, we’re known for creating custom retail displays and fixtures. But some of our most successful projects are things customers never even see.
Take this little yellow plastic part we manufacture for Kohl’s.
It’s not flashy. It doesn’t sit on a store shelf or showcase a product. In fact, most Kohl’s shoppers will never know it exists.
But behind the scenes, this small component became a big success.
The Challenge: Solving a Behind-the-Scenes Problem
Kohl’s needed a solution for a specific challenge in its backroom operations.
It wasn’t a large display or an elaborate fixture. It was a small, functional component that needed to do its job reliably.
That’s where BAW Plastics came in.
Our team was presented with the problem and given the opportunity to develop a custom solution.
The Solution: A Little Yellow Piece of Plastic
BAW’s Frank Dusch took on the challenge. He worked through the design, selected the appropriate material and color, and determined how to manufacture the component to meet Kohl’s needs.
The result? A simple yellow plastic part designed for a very specific purpose.
No unnecessary bells and whistles. Just a practical, customized solution to a real problem. And sometimes, that’s exactly what a customer needs.
The Results: From One Order to Every Kohl’s Store
What started as a small project quickly became something much bigger.
Kohl’s was so pleased with the solution that it doubled its original order.
BAW Plastics ultimately manufactured and shipped the components to every Kohl’s store across the country.
And the story doesn’t end there. Kohl’s continues to use the part today, and BAW has received additional orders over the years, including a recent reorder.
One small component. A nationwide rollout. A lasting customer relationship.
Have a Small Problem That Needs a Smart Solution?
Not every project needs to be big to make a difference.
From custom plastic components and specialty parts to retail fixtures and nationwide rollouts, BAW Plastics has the experience and capabilities to bring your ideas to life.
Have a part you can’t find? A process that could work better? Or an idea that needs to become a reality?
We’d love to take a look.
Let’s make something great together.