Behind the Build: 150 Cases

At Packhorse Limited, we believe that behind every rivet, bolt, and cut lies a story of precision, craftsmanship, and scale. One of our largest and most ambitious undertakings to date saw the production of 150 fully custom flight cases — designed, manufactured, and delivered alongside our regular workload without missing a beat.

But this wasn’t just a production run. It was a true collaboration.

What Made It Possible?

Delivering a project of this magnitude required more than just machinery and materials — it demanded the coordination of an expert team, a rock-solid supply chain, and weeks of meticulous planning and execution.

Together with our dedicated in-house staff and in close partnership with our trusted suppliers, we brought this project to life on a tight timeline and to our exacting standards. Every department played a vital role — from procurement and design, to fabrication, assembly and logistics.

Here’s what went into making it happen:

• 66,900 rivets

• 4,200 bolts

• 1,626 meters of aluminium extrusion

• 7,524 meters of CNC cutting

• 115,050 individual components

• 825 meters of deep hole drilling (yes, really!)

These aren’t just numbers — they represent the countless hours of skilled labour, the strength of our supplier relationships and the efficiency of our production systems. From the initial client brief to the final delivery, every element was coordinated with care and precision.

More Than a Manufacturing Project

This project stands as a testament to what Packhorse Ltd does best: high-volume, high-quality case manufacturing, delivered on time and with attention to the smallest detail.

It’s also a powerful reminder of what can be achieved when a team pulls in the same direction — solving problems, managing complexity and delivering results at scale.

Let’s Build Together

If you’re looking for a partner who can turn complex requirements into practical, durable flight cases, we’d love to hear from you. At Packhorse Ltd, we’re here to ensure your equipment travels safely, so you can focus on what you do best.

For more information on how Packhorse Ltd can meet your custom flight case needs, please contact us directly. We are here to ensure your equipment travels safely, allowing you to focus on what you do best.