Card Factory

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Card Factory

Factory resetting a major card supplier’s direct-to-store delivery model.

When Card Factory needed a logistics partner who could keep pace with rapid store expansion, they came to Expect. Here’s how we grew their direct-to-store network from 250 stores to over 750, while improving visibility, sustainability and service through every peak.

The challenge

Card Factory was growing fast, and its existing direct-to-store delivery network couldn’t keep up. Capacity and visibility were limited, putting pressure on store operations, while rising demands for sustainability, reverse logistics and peak-season service levels needed a partner who could do more than deliver. They needed one who could scale with them.

Objectives for growth:

Build a scalable, cost-effective delivery network to support rapid store expansion
Improve service quality and communication between distribution and store teams
Support sustainability goals by reducing environmental impact and improving fleet efficiency
Strengthen supply-chain performance through peak trading, where reliability matters most

We partnered with Expect because we recognised the need to partner with a progressive, solutions-based provider who could work at pace and support our business growth.”

Card Factory

The solution

We designed a scalable logistics operation built around Card Factory’s growth. At its core was a newly implemented outbase model and a dedicated branded fleet, expanding the direct-to-store network while keeping it cost-efficient.

We strengthened store visibility through enhanced tracking and delivery-window technology, maintained nationwide coverage via the Palletline network, and took full responsibility for end-of-season reverse logistics to improve speed and control. The introduction of electric vehicles supported their journey to net zero, creating a reliable, efficient operation that performs year-round.

Expect have worked hard to drive value to our business whilst improving our service levels with retail stores. They’ve introduced SMS ETA messaging for all store deliveries, allowing our retail colleagues to efficiently plan for their deliveries’ arrival times. Expect have also taken on ownership of our end-of-season reverse logistics operation and improved the control, store service and speed of the returns process.”

Card Factory

The result

250 to 1000+ stores

Direct-to-store delivery scaled threefold through the new outbase model, enabling cost-efficient growth.

More visibility and control

Enhanced tracking and delivery windows improved coordination with store teams and tightened planning.

A greener operation

Electric vehicles and streamlined reverse logistics support Card Factory’s net-zero goals and speed up end-of-season processing.

We have a number of progressive initiatives planned together to drive further efficiency and service levels, and value the strong relationship and ‘one team’ spirit between our two businesses.”

Card Factory