Macfarlane Packaging have been working with Childrensalon for over 10 years, continually improving their packaging to help them perfectly present their products, while reducing their packaging’s impact on the environment.

The Brief

Childrensalon challenged Macfarlane with a new project to provide sustainable, luxury gift packaging and transit packaging for their products. The new packaging designs needed to:

• Reduce the amount of packaging material being used
• Increase parcel security to protect the designer garments
• Enhance customer experience
• Lower transport costs
• Cut emissions associated with packaging

The Solution

Rising to the challenge, Macfarlane’s team of packaging experts suggested two key solutions:

Optimising the highest use cardboard boxes from Childrensalon’s packaging range.

The redesign included significantly reducing material weight across Childrensalon’s small and medium boxes, while maintaining the protection they provide. The new cardboard boxes are also made with over 60% recycled content, further enhancing their sustainability. Childrensalon’s account manager, also suggested reducing the use of a deep medium box and swapping to a less deep carton, to provide further environmental savings.

Providing new, sustainable alternatives to traditional magnetic gift boxes.

Childrensalon’s new gift boxes are made using 100% recycled grey board, which is FSC® certified. Macfarlane’s experts recommended removing magnets, so the new designs are 100% kerbside recyclable. The boxes were also designed to be collapsible and reusable, so end-users can repurpose them if they want to.

The Results

Optimising the highest use cardboard boxes from Childrensalon’s packaging range enabled them to remove 54 tonnes of material from their supply chain each year.

The cardboard box optimisation also enabled Childrensalon to remove 44 tonnes of CO2e from their supply chain annually. This is the equivalent to 5.3 million smartphones being charged or over 100,000 miles being driven in an average passenger car.

In addition, by reducing use of their deepest medium box, their packaging could be delivered in fewer vehicles. This provided an additional transport CO2e saving of 0.36 tonnes, equal to over 43,000 smartphones being charged.

The gift boxes enable approximately 10.89 tonnes of material to be recycled, compared to the previous solution.

What Childrensalon has to say

“Working on this packaging project with Macfarlane to develop new and varied cardboard box sizes has been an incredibly rewarding experience.

By combining optimised box dimensions, the right materials and a user-friendly unboxing experience, my team and I have been able to significantly reduce paper use and volumetric weight. This has led to notable material savings, enhanced customer experience and lower CO2 emissions.

This project highlighted the critical impact of smart packaging design on sustainability. Macfarlane’s commitment to innovation and environmental responsibility made it possible to achieve these impressive results. My team and myself are proud to have contributed to an initiative that not only benefits our business but also supports our planet.”

Head of Logistics – Outbound for Childrensalon

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Application

Exporting 38 brushed alloy automated blind systems to Saudi Arabia, our customer required a sturdy packaging solution that could provide high levels of protection on the long journey.

It was imperative that the high value, fragile systems arrived in pristine condition, ready for installation.

Damaged shipments would incur reputational damage as well as additional export, return and replacement costs.

Solution

We worked with customer supplied CAD drawings of the systems being packed and utilised our SolidWorks® design software. This allowed us to tailor the packaging specifically to the contents.

We created a solution that combined a bespoke Ply-Batten case and CAD cut Stratocell® inserts, tight fitting end caps and centre supports, providing optimum protection and support.

Results

The bespoke packaging we have designed matches the customers own product design, offering the best protection for exporting heavy, fragile and easily damaged products. Our packaging conveys the value of the product it is designed to protect, demonstrating the customer commitment to delivering quality.

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Application

Shipping heavy, sensitive printer rollers susceptible to damage and the incidence of “flat spots” which affect print quality, our client wrapped each roller in bubble wrap before placing it into an outer box for storage or shipment.

The bubble wrap left marks on the rollers if put into storage for too long and did not reflect the quality of the brand. It also proved difficult for the end user to dispose of the packaging responsibly.

Solution

Working around samples provided by our client, we used SolidWorks 3D CAD software to design protective corrugate end supports which held the rollers centrally in the box, eliminating damage and the incidence of flat spotting. Our software and CAD table capabilities allowed us to produce an optimal design quickly and efficiently, in 100% recyclable materials.

Results

The new solution not only offered great protection with the minimum of packaging, it also removed hundreds of meters of plastic bubble wrap from their packing operation. The new solution reflects the quality of the customer brand and their commitment to quality.

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Customer: A leading manufacturer of heavy duty turbines

Application

The customer needed a more sustainable packaging solution for their turbine blades that are being shipped globally.

They wanted to remove the plastic corrugated outer solution and reduce the foam inserts inside the pack -whilst improving the level of protection for their products.

Solution

A heavy duty, die cut corrugated outer was designed to replace the existing plastic corrugated case.

Using in-house 3D CAD software, SolidWorks, internal corrugated cellular divisions were designed, enabling operators to customise fittings to suit different blades, allowing 1 pack design to suit all blade specifications.

Results

The customer has a plastic free outer packaging solution with significantly reduced internal foam inserts that delivers optimum product protection.

With a multi-functional pack design they have been able to consolidate their range of packaging, reducing storage space.

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Customer: A global manufacturer in aerospace, defence and power with a presence in 16 countries

Application

Shipping a variety of sizes and shapes, our customer required a solution that could protect high value, sensitive test equipment from the rigours of a 6 week sea-freight journey to the USA.

The solution needed to maximise shipping container space and be ready to use in just a few days.

As the equipment was irreplaceable, it was imperative that it arrived without damage.

Solution

Macfarlane designed bespoke softwood frame ply cases for durability, with a drop down front for ease of accessibility for loading and unloading. The equipment was bolted in place within the case.

The cases were lined with a woven polypropylene and the equipment vacuum packed in foil bags with silica gel, this provided protection from moisture and rust in the harsh sea freight environment. The addition of Stratocel cushioning ensured high levels of shock absorption, protecting sensitive equipment from the risks associated with impact.

Finally, stencilled messages were added to the outer case to advise handling instructions whilst in transit.

Results

Turned around in just a few days, our solution provided size and shape uniformity. This allowed all the pieces of equipment to fit into a single container with maximum protection, ensuring safe delivery to its final destination.

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Customer: A leading developer of industrial and commercial inkjet, thermal transfer, digital and laser printing products

Application

With a view to improving the sustainability of their packaging, our customer requested an evaluation of materials that could have a lower environmental impact.

We were tasked to find 3 new concepts that would best suit their latest manufacturing project and deliver high levels of protection.

Solution

Macfarlane undertook a programme of analysis of 8 different materials, and conducted compression (taking into account climatic allowance), vibration and shock/impact tests on each.

For comparison purposes, the materials test included bamboo, EPS, EPP, corrugate, fibre pulp, mushroom and plastic.

Each material was rated on it’s test performance results as well as it’s benefits and disadvantages—factors like availability, storage space required and manufacturing MOQs.

Results

We delivered a full report of material analysis to the customer, enabling them to make an informed choice for their packaging materials, supporting their sustainability objectives and shaping their future.

The final solution consisted of a corrugated board base with top dividers to replace existing polyethylene foam fittings.

The pack was extremely lightweight, easy to recycle, had excellent structural strength and delivered material cost savings of 12%

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Promoted by an industry-wide rise in packaging prices in 2020 and 2021, Epicurium were looking to streamline their packaging materials and associated costs. At the same time, a rise in demand meant that Epicurium were also looking for ways to improve their productivity.

The Brief 

• Introduce packaging solutions to help Epicurium reduce their operational costs
• Solutions need to help increase productivity and manage demand

The Solution 

Experts from the Macfarlane Packaging team suggested several solutions, including:

Swapping from plastic tape to gummed paper tape

Epicurium were sealing boxes with standard plastic packing tape. This involved using up to 14 strips per box – an average of 7 metres.

Swapping to gummed paper tape has the potential to unlock cost-savings, as well as reduce material use. Only two strips, measuring 1.6 metres were required to seal each box.

Redesigning packing areas

To tackle efficiency challenges, Macfarlane re-designed Epicurium’s packing area. This meant that all packing materials and equipment were within easy reach and the design minimised down time that was being spend fetching packing materials from other areas in the warehouse.

The Results

78% reduction in packing tape material used

Less paper tape was needed vs. the previous solution

£2,000 saving per year

Offsetting rising costs in other areas by lowering tape costs

100% recyclability improvement

Tape can now be recycled with cardboard boxes

Improved productivity

The new packing area helped create a more efficient environment

What Epicurium have to say

“We work alongside 100s of retailers, all of which have their own sustainability goals. We’re increasingly seeing our snack brands move to plastic-free packaging too. Working with Macfarlane, and their initiatives, has meant we keep pace and help us in our aim of becoming a plastic-free business.”

Head of Technical & Operations

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The brief was to create a cost-effective packaging solution that was quick to assemble, easier to open and recyclable at kerbside, it also had to be suitable for four ready meals and could remain at a temperature between 2-8 degrees for a minimum of 30 hours.

Macfarlane Packaging experts from our Temperature Controlled Packaging team and innovation lab collaborated to design a unique chilled packaging solution for Parsley Box.

The pack features a unique one-piece corrugated cardboard design that contains a top level cavity to hold dry ice in the summer months. Combined with ice sheets, the solution was able to preserve in pack temperatures for 30 hours in testing. Both the outer and inner packs are kerbside recyclable, and the outer material of the ice pack can be recycled at supermarkets with bags as its made from LDPE.

Parsley Box’s new solution exceeded their brief and delivered:

• Improved productivity – the pack is quick to assemble, freeing up labour resource.
• An enhanced customer experience – it’s now easy to open.
• Less impact on the environment – the pack is now 100% recyclable.
• Lower costs – the pack provided an annual saving of over 20% on delivery costs.

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Partnering 1,400 emerging and global technology brands and over 50,000 resellers, e-commerce operators and retailers globally, they are committed to minimising the impact of business operations on the environment. Sustainability is integral to their overall strategy to build a long term, profitable business.

Macfarlane worked in partnership with Exertis at 3 UK sites to identify opportunities to reduce carbon emissions.

Analysis of stretch wrap and pallet top sheets revealed opportunities to reduce material by 24% whilst ensuring load containment. This removed 17.6 tonnes of plastic, equating to 45.4 tonnes of CO2e emission in plastic manufacturing based on UK Government material manufacturing averages.

This project is ongoing.

Stage 2 has identified removal of a further 19.3 tonnes of plastic.

Stage 3 will involve Macfarlane Group Europe implementing this process at other Exertis facilities.

“As part of the Exertis sustainability focus and through our strategic partnership with Macfarlane Group, collectively we have identified and removed 18 tonnes of Single Trip Plastic and 45 tonnes of CO2e from our UK Supply Chain for 2020 without compromising quality or security.”
Alan Lynch Global Logistics Director

To find out more about Exertis and their products, visit: https://www.exertis.co.uk/

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