By changing how you package items and improving your packing methods, you can save money and make your supply chain more efficient.

This blog post explores how increasing business costs affect companies and how optimising packaging can help reduce these expenses. We’ll also consider strategies for successful implementation.

Understanding the impact of rising business costs

Today, businesses are facing tough economic challenges. They are dealing with more competition and changing markets and costs are rising. These factors are causing financial instability in all industries.

Factors such as inflation, changing consumer behaviour and legislative changes are contributing to increased costs. Higher energy prices are increasing raw material costs, while labour costs are rising faster than the cost of products. This is contributing to labour shortages in the UK as businesses struggle to keep salaries competitive.

When it comes to overall business expenses, the cost of packaging plays a significant role. It’s an essential component of product delivery and protection, and where inefficient packaging processes can contribute to higher packing costs.  By optimising packaging processes, businesses can reduce expenses, enhance operational efficiency and improve their bottom line.

What is packaging optimisation?

Packaging optimisation improves design, reduces material use and enhances efficiency in the packaging supply chain to minimise environmental impact.

The right packaging solutions save time by speeding up the packaging process, as well as improve the utilisation of storage space on site. This can ultimately lower costs for labour, warehousing and shipping.

How packaging optimisation can deliver cost savings

Efficient packaging is crucial for businesses looking to gain a competitive edge. It has an impact right across the supply chain, including:

• Material reduction: By using the right type and size of packaging for your products, you can significantly reduce the amount of materials needed and reduce your packaging costs.
• Packaging taxation: By reducing material use, you will also reduce the amount of taxation paid on packaging usage on schemes such as PRN (Packaging waste Recovery Notes) and the forthcoming EPR (Extended Producer Responsibility) scheme where packaging enters UK households. By switching to recycled content plastics, you can also remove the additional costs of PPT (Plastic Packaging Tax).
• Labour cost: The right pack design and packaging automation can help your team to work smarter and faster, removing the need for temporary staff at peak times and allowing you to move team members to more productive tasks.
• Reducing shipping costs: Optimised packaging can improve parcel cubage, allowing you to fit more shipments on a pallet / courier vehicle to maximise payload and reduce the cost of delivery.
• Reduced product damage: The right packaging should deliver high levels of product protection, particularly for fragile items. This will reduce the incidence of damaged products, product waste, write-off and disposal costs as well as double order handing.

Packaging optimisation also has a positive impact on your business sustainability goals by reducing material use, moving to improved pack recyclability and lowering the number of delivery vehicle runs. This can support supply chain accreditations, reduce carbon emissions and help you to hit those ESG (Environmental, Social and Governance) goals.

Strategies for packaging optimisation

So, now we understand the advantages of packaging optimisation, what strategies can you implement to deliver significant savings through the supply chain?

Here are some key strategies to consider:

Using lightweight yet durable materials

One effective way to reduce the cost of packaging is by using lightweight materials that still offer durability and protection. There may be options to switch to a different corrugate fluting in a cardboard box for example, or a lighter gauge stretch wrap. But it’s important to strike the right balance of material and not compromise the safety of your products. By hitting the sweet spot of weight and strength, companies can optimise packaging while keeping expenses in check.

Redesigning packaging

When did you last review the types of packaging you’re using and how it performs? Often, little consideration is given to the packaging and its simply reordered time after time because “it’s always been used”. Think about ways to make the pack better by choosing designs that are faster to pack, use less material, and require less storage space. Smart packaging designs can all have a positive impact on cost across your operation.

Customising pack sizes to fit product dimensions

Another strategy to be cost effective is by customising pack sizes to fit products more efficiently. By eliminating excessive void spaces with a range of box sizes, businesses can minimise the amount of packaging material required and reduce shipping costs. Customised packaging not only saves money but also enhances the customer experience by ensuring products arrive in perfect condition.

Implementing automation in packaging processes

Automation can greatly improve the efficiency of packaging operations, leading to cost savings in the long run. By automating tasks such as filling, sealing and labelling, businesses can streamline their packaging processes, reduce errors and increase productivity. This not only helps combat rising costs but also allows employees to focus on more value-added tasks.

Reviewing how you order packaging

Optimisation also includes looking at the packaging procurement process. Do you order in bulk to get the best price, but then find you have racking full of packaging? Keeping excess inventory takes up space and ties up cash flow. This means packaging is bought but not needed, sitting unused for months. 

Consider a stock and drip (or JIT) option, where packaging is delivered in smaller quantities and only as you need it. This not only improves cashflow but also has the potential to unlock space in your warehouse for more product to sell at peak times or, even increase production space.

What factors should we consider when optimising packaging?

When improving packaging, think about:

• The size and weight of the product being packed
• How fragile it is
• Storage and transportation needs
• Any relevant industry rules or guidelines

The primary purpose of packaging is to protect your products and deliver them to their destination in pristine condition. Packaging optimisation should not compromise the safety or security of your products.

How Macfarlane Packaging can help

Macfarlane Packaging offers a range of innovative solutions to help businesses rethink their packaging and reduce operational cost.

We offer a free packaging review to support you to use less packaging and improve pack recyclability. We can speed up your packing time and help you to fit more products on your delivery vehicles.

We can also help you to prepare for the forthcoming EPR taxation to minimise the cost on your business.

Why not contact us today?

The post How to reduce business costs through packaging optimisation appeared first on Macfarlane Packaging.

Last year, 8.8 million wine bottles were sold in the UK, marking a 10% increase from the previous year. This represents a continuous growth trend over the past five years, with no signs of slowing down.

As many customers opt for online shopping due to its convenience and ease, ensuring that your bottles arrive in perfect condition is crucial.

This blog post looks at why bottle packaging is important, examines various options available and provides advice on selecting the right bottle packaging for your products.

The importance of bottle packaging

The right packing materials protect your bottles from damage and ensure your customers can fully enjoy their gifts.

When any product arrives damaged, online retailers need to think about:

• The cost of product replacement
• The damage to your brand’s reputation and the customer’s experience
• The expense and hassle of reverse or replacement logistics
• The environmental cost, as the carbon footprint of transactions increases when products need to be replaced

All this adds to your operating costs and can greatly influence how customers view your brand and whether they will buy from you again. Therefore, it is essential to select the appropriate bottle packaging to fulfil its purpose.

Types of bottle packaging available

The choice of the right bottle packaging can vary based on various factors. Below are a few options available.

1. Airsac® inflatable bottle packaging

Airsac is an innovative, inflatable packaging solution, made of 2% film and 98% air. It is supplied flat and inflated on demand. This makes it a great lightweight, storage saving alternative to traditional bottle packing methods, like polystyrene and bubble wrap.

It is suitable for transporting one, two, three, six or 12 / 70cl wine bottles. Customers can purchase the bags individually or in combination with an outer cardboard box for a comprehensive packaging solution.

A hand pump or air compressor is necessary to inflate the bags and there are automated inflation options available for high-demand environments. Airsac bottle packaging contains 50% recycled content and the inflatable bags can be recycled at large supermarkets.

2. Flexi-Hex® bottle packaging

Flexi-Hex is an excellent, paper-based bottle packaging solution. It features a unique honeycomb design that expands to snuggly fit around bottes for exceptional transit protection.

This eco-friendly bottle packaging choice is completely kerbside recyclable, made from up to 85% recycled content and renewable paper material.

You can choose from one, two and three bottle options for online retail that include the sleeves and shipping boxes, as well as single bottle gift packs.  

3. Cardboard bottle boxes with dividers

Cardboard bottle packaging, such as bottle boxes with dividers, are widely available as an “off-the-shelf” solution or can be tailored to fit your specific needs.

You can choose from single bottle boxes or packages designed for cases containing six or twelve bottles if you are selecting from stock items. All cardboard bottle packaging is kerbside recyclable, which is good for the environment. However, it’s important to ensure the bottle box you choose can support the weight and dimensions of your products to prevent damage during shipping.

4. UPS approved spirit packs

UPS approved spirits packaging is a bottle packaging solution created by Macfarlane Packaging in collaboration with UPS and Sealed Air.

It is available in four distinct styles, catering to a variety of spirit bottle shapes and sizes. This includes a traditional bottle pack designed to provide an ideal fit for shipping wine bottles. Each pack features an outer cardboard box with a Korrvu insert that securely holds the bottle in place, offering a good transit protection for breakable goods.

5. Polystyrene bottle packs

Moulded polystyrene is a traditional bottle packaging option, offering a high level of transit protection. It’s widely available to transport wine in packs for one, two or three bottles with peace of mind.

Polystyrene bottle packs can be quite hard to dispose of, which may lead to a negative customer experience and increased packaging waste. Additionally, this type of bottle packaging requires a significant amount of storage space. The extra bulk can also affect your shipping and courier costs, as the dimensions and weight of your parcels may be larger. This, in turn, can lead to higher CO₂ emissions during transit.

6. Moulded pulp packs

Made from paper pulp fibres, moulded pulp bottle packaging is an environmentally friendly, biodegradable alternative to polystyrene bottle packs.

It can be manufactured as endcaps to fit the top and bottom of a bottle or tailored to a specific bottle format.

This solution is easy and straightforward to pack, however, doesn’t provide as much protection as some of the other bottle packaging we’ve mentioned before. It can also be bulkier to store.

Choosing the right bottle packaging for your business

The bottle packaging you need will depend on several factors, including:

• How many bottles you send in each shipment
• The size of your bottles
• The weight of your bottles
• How damage prone your bottes are
• If your bottles are going in multi-pick packs  
• The storage space available in your packing area or warehouse
• How important the environmental credentials of your packaging are to your customers (and your own environmental impact goals)

Take a look at this concise bottle packaging comparison guide to find the most suitable bottle packaging option for your products, budget and requirements.

Support with bottle packaging

If you are unsure which bottle packaging solution is right for your products or would like to discuss your specific requirements, get in touch today.

Our team of friendly packaging experts, armed with extensive knowledge and a wide range of bottle packaging options, is here to help you find the perfect solution for your business needs.

The post How to pack wine bottles appeared first on Macfarlane Packaging.

Before Christmas, consumer orders increase significantly. This increase in orders puts a lot of pressure on logistics teams and packing operations.

In this blog we’re going to look at three ways the right packaging and packaging equipment can help get your warehouse peak season ready.

What is peak season?

The busiest time for retail in the UK is peak season, which lasts from November to January. This is because of events like Black Friday, Cyber Monday, Christmas, and the January sales, which drive a surge in customer orders.

The higher demand can greatly affect the supply chain. Logistics teams will need to handle more stock, manage complicated inventory, and make sure orders are fulfilled on time. Increased order volumes can lead to bottlenecks in picking, packing, and shipping processes, potentially delaying deliveries and affecting customer satisfaction. Operational agility is key to respond to fluctuations in demand.

How to prepare for peak season?

Preparing for peak season is about managing increased sales and ensuring a seamless, efficient supply chain that can handle the pressure and deliver exceptional service.

So, how can you get your warehouse ready for peak?

Identifying common bottlenecks

The first thing you should do is try and identify and common bottlenecks.  This can be pivotal in maintaining your warehouse efficiency.

Key metrics to help you review pressure points are:

• Picking accuracy – Miss-picks can be a sign that something isn’t working or that capacity is being outstripped by demand.
• Packing times – During high-pressure times, packing times can be a bottleneck if processes aren’t efficient and packing materials aren’t easy.
• Dispatch lead times – Slower dispatch times can signify that current processes need to change to help meet demand spikes.
• Damages – An increase in damages can be an indicator that packing isn’t being completed properly or that the packing materials being used aren’t sufficient.

Once you’ve considered bottlenecks, you should think about the packaging materials you’re going to use during peak.

Optimising packaging for peak season

Efficient packaging is a cornerstone of successful peak season operations. The right pack can help you pack goods faster, keeping your production line moving smoothly and quickly, so you can deliver them on time! Here’s how optimised packaging can impact your operation:

• Reduce damages and returns – By ensuring you have the right packaging protection. This can minimise the need for double picking and delivering orders (reducing overall cost and sustainability).
• Improve parcel cubage – This will increase the number of goods that can ship on a single vehicle and optimise your vehicle delivery capacity. Reducing the size of parcels can prevent the necessity for additional void fill. This can help in saving materials, cutting costs, and decreasing your carbon footprint.
• Improve sustainability – For example, switching to recycled content materials and improving recyclability, can all have a positive impact on supply chain sustainability.
• Improve storage space – Consider the storage footprint of your packaging solution, a rethink in design could improve palletisation and reduce the number of pallets held on site.  It may also be worth looking at how your packaging is delivered. Buying in bulk for the best price can tie up space that could be used for additional sales stock during busy times. Discuss with your supplier the option to make frequent small deliveries, which can help reduce the need for large storage space.

A packaging review can help you to identify the right packaging for your products, to speed up packing time, improve parcel cubage and reduce damages.

Standardise your packing process

Standardising your packing process can improve efficiency and help maintain packing consistency. Here are 3 ways to help you improve your packing process:

Review – the current packaging that you are using and identify opportunities to reduce the amount of time it takes to pack out. For example, switching from a standard 0201 shipper to a crash lock base box that pops into shape, can significantly reduce the time needed to assemble the pack.

Develop – clear packing guidelines for your team. These should include instructions on how to pack different types of products, when void fill materials should be used, and techniques for sealing completed packs. Frequent training ensures that packaging is applied in the right way, driving consistency in the amount of packaging material used and reducing the potential for damage in transit.

Consolidate – the packaging your team needs in one place. A dedicated packing station, equipped with everything they need, will reduce the time spent searching for the appropriate packaging materials and keep the packing process organised.

Streamlining warehouse operations

To keep up with spikes in demand it’s essential that your warehouse operations are efficient and effective. Consider the workflow of space and look for opportunities to strategically place popular products and packaging for easy access. This will help to minimise unnecessary movement and maximise productivity.

A well-organised warehouse with no obstacles is essential for a smooth operation. A layout should be considered, following the flow of picking, packing and dispatch.

Here are some quick fixes that you could put in place to solve some common warehouse issues.

• Increase storage for seasonal stock with temporary shelving or pick bins to help keep stock off the warehouse floor, this will protect staff from trips and falls as well as protecting product from damage. It also makes products easier to find!
• Clear labelling of products on shelving and pick bins will help to reduce the incidence of mispicks.
• Keep litter and debris to a minimum with strategically placed rack and packing station sacks. Quick and easy to install, they will provide a space to dispose of waste and keep the warehouse tidy.
• Utilise packing stations to improve warehouse flow, a well organised pack bench will support faster packing times. Consider a customised option which can incorporate shelving, separators, fixed roll holders and dispensers. This puts everything needed to pack out orders at the operators’ fingertips. It’s worth noting here that anti-fatigue matting should be used at pack benches, especially if you have hard concrete floors. These mats ease the pressure on feet and legs and reduce fatigue from standing for long periods of time.
• Automate repetitive tasks where possible. Large scale packaging automation will be a challenge to implement so close to peak season but, you can still consider “plug and play” systems like electronic tape dispensers and automated void fill systems to speed up packing times and reduce operator pack touches.

Support with your packaging and packing operations during peak

It’s not too late to prepare your warehouse for peak season. A considered assessment of your current layout, processes and packaging can help you achieve a smooth-running operation in preparation for increased seasonal demand.

Streamlining your warehouse layout, installing packing automation and strategically playing your products will help to boost productivity and remove bottlenecks that can impact your dispatch times.

Macfarlane Packaging is here to help you get operation ready for the busy season ahead. Our range of warehouse products, automation systems and innovative packaging solutions can reduce packing times and increase operational efficiency. Contact us today for your free packaging review.

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Custom packing benches are a great solution to optimise your packing process, as they can be tailored exactly to your needs and customised according to specific requirements.

In this blog post, we’ll explore how you can maximise productivity by introducing custom pack benches to your operation. We will look at some of the main benefits of an efficient packing station and how bespoke packing benches can help achieve them.

We will also discuss ways you can customise your pack stations to fit your specific business needs, as well as investigate cost considerations and return on investment. 

The benefits of an efficient packing station

A well-organised packing area is crucial to ensuring your packing operation runs as smoothly as possible. Some of the main benefits include:

1. Increased efficiency and speed of packing

Your packers will be able to pack and dispatch products faster if they have all the necessary packing materials at hand. Disorganised shelves and misplaced items may cause delays and impact the speed of your packing lines. A well-organised packing area will help avoid mistakes and save your team time searching for products and packing materials they need for a fast and efficient product dispatch.

2. Maximised space utilisation

Organising and configuring your packing benches is essential to maximising room in your warehouse. Packaging stations that are tailored to your space will help optimise your warehouse floor.

Making sure your warehouse is laid out as efficiently as possible will not only help you better utilise space but also ensure your packers don’t need to walk long distances to pick up necessary items. This, in turn, will help enhance efficiency and avoid unnecessary downtime.

3. Enhanced packer comfort and safety

Ensure your team is comfortable and happy with their work area. It will be hard for them to pack efficiently if they are tired or need to twist a lot to pick up packing materials.

A well-organised pack bench with packing items organised between hip and shoulder height will help prevent fatigue and increase productivity.

Customisation to meet specific business needs

Custom pack benches can be tailored to your specific requirements, allowing you to simplify your packing processes, boost efficiency and make the most of your space.

There are many features to choose from and you may also want to consider adding some of the tools that can help you pack faster and more efficiently. Options include:

• Organisational tools, such as trays and dividers to keep packing materials in order and make them easy to find

• Efficiency tools, like dispensers, roll holders and cutters to maximise productivity
• Ergonomic tools, including adjustable monitor arms and keyboard droppers that reduce strain
• Mobility and stability tools, such as braked castors and levelling feet, ensuring benches can be moved if needed

Cost consideration and return on investment

Flexibility in the design of custom pack benches allows you to select solutions that meet not only your packing needs but also your budget. The benefits of custom packing benches will also help you save money in the long term, and this should be considered when calculating ROI.

With well-structured packing benches in place, your products can be shipped quickly, meeting deadlines, and satisfying your customers. A more efficient packing area will result in enhanced productivity, happier staff, and quicker product dispatch.

Custom packing benches available from Macfarlane

Our new range of custom pack benches have been designed to take up less space and increase efficiency in your packing processes.

To make things simple, you can choose from 4 main pack bench designs and add 20 additional part options for greater flexibility with your design.

Customisable pack benches are made from high-quality, heavy-duty steel to withstand even the toughest warehouse conditions. They are assembled to order in the UK, ensuring quality craftmanship, and delivered ready-to-use for ease and convenience.

Contact us today to find out more about our custom pack benches and the options available.

The post How to Maximise Productivity with Custom Packing Benches appeared first on Macfarlane Packaging.

Product packaging is one of the key areas where companies can make a significant difference. According to a survey published by Statista, 81% of customers prefer eco-friendly packaging and 80% believes that online deliveries arrive overpacked.

A switch to sustainable packaging will help businesses reduce their environmental footprint and address the concerns of eco-conscious consumers.

In this blog post, we’ll explore six sustainable packaging switches. We will also look at why sustainable packaging matters, how to make your packaging eco-friendlier and how we can help you achieve your sustainability goals.

What is sustainable packaging?

Sustainable packaging is packaging that minimises its environmental impact from the time it’s manufactured to the time it’s disposed of. This includes the packaging’s design, the materials used to make it, how it’s handled, and if it can be reused or recycled after use.

Other terms for sustainable packaging include eco-friendly packaging or environmentally friendly packaging.

Why is sustainable packaging important?

Sustainable packaging reduces carbon emissions and helps combat climate change. It also conserves resources and reduces packaging waste. All in all, it’s a better option for the planet and your business.

It can also help you comply and reduce additional costs of recent packaging regulations, including Extended Producer Responsibility (EPR) and the Plastic Packaging Tax.

How to make your packaging more sustainable

There are several ways to make your product packaging more sustainable, including using less material to do the same job or switching to an eco-friendlier alternative.

Packaging solutions that can be reused, recycled or contain recycled materials will also typically reduce environmental impact and support the broader transition to a more sustainable economy.

The right packaging solution will protect your products on their journey to the consumer, while saving you money on materials, storage and transportation. It will also help minimise product damage in transit, therefore, you will spend less on issuing replacement and processing returns.

6 sustainable packaging switches

Below, we have listed 6 different sustainable packaging swaps, which can help make your supply chain more eco-friendly.

1. Paper vs Plastic Tape

Paper tape is an eco-friendly alternative to traditional plastic packing tapes.

It is available as self-adhesive, gummed paper or masking tape, and comes in a wide variety of roll sizes and lengths. Paper tape can contain different types of adhesives, which can affect its properties. Some paper tapes offer permanent sealing, like gummed paper tape, while others are meant for temporary use.

Paper tape can be recycled together with cardboard boxes, making the recycling process easier for your customers. It can also help significantly minimise material waste, contributing to a reduction in your CO₂ emissions – take a look at our case study to find out more.

2. Bubble Wrap® IB Film vs Traditional Bubble Wrap

Bubble on demand is an excellent solution for increasing productivity, saving space and reducing material costs.

Bubble Wrap® IB film can be shipped and stored flat, and then inflated on demand with a simple to use inflator.

This is a great space-saving solution – one pallet of Bubble Wrap® IB film is equivalent to 90 large bundles of traditional bubble wrap.

The IB film also takes up less space on delivery vehicles, resulting in the reduction of material deliveries by 97%, lower transport costs and carbon footprint.

To find out more about this product, take a look at our blog article: Why Choose Bubble On Demand vs. Bubble Wrap.

3. Recycled Content vs Virgin Kraft Cardboard Boxes

Cardboard boxes made from recycled materials provide a sustainable and environmentally friendly packaging option.

These high quality, durable boxes are made with up to 100% recycled materials, so choosing this solution can have a positive impact on the environment and your brand reputation.

Read our recent blog post for more details – The benefits of using recycled content boxes.

4. Corrugated Cardboard vs Wooden Pallets

Corrugated cardboard pallets are a lightweight alternative to traditional timber pallets. They weigh only about 4kg each but are very strong and durable and can hold up to 750kg.

The light weight of the pallets can contribute to reducing your overall shipping weight, and you can recycle them at the end of their lives too, making them a sustainable choice. They are also exempt from ISPM15, meaning you can ship them worldwide. Cardboard pallets are easy to handle (no splinters or nails) and can be collapsed for storage, helping optimise space in your warehouse.

5. Stretch Wrap Reduction

If you’re using pallet wrap and looking for ways to reduce the amount of material you’re handling, lower micron stretch films are a good option. Stretch films with recycled material content are also available, helping you comply with packaging legislations, including Plastic Packaging Tax.

For machine applications, there’s a wide selection of machine applied stretch films starting at 10 microns, with up to 30% recycled content and up to 300% stretch. These solutions will help you use less material to wrap each pallet, reducing costs and environmental impact, without compromising product safety in storage and transit. To find out more, read our blog article: 5 Ways to Reduce the Cost and Environmental Impact of Your Stretch Wrap.

6. RecyCold® Climaliner Shipping Packs vs. Foil Lined Chilled Packaging

RecyCold® Climalinershipping packs are a new, innovative chilled packaging solution that combines RecycoolMe boxes with new RecyCold® Climaliner insulated liners.

The liner is filled with Ranpak’s Geami honeycomb paper and offers up to 48 hours of insulation against temperature fluctuations for chilled, frozen, or ambient products.

Recyclable, 100% paper-based, made from sustainable materials and vegan friendly, the solution is a great substitute for foil lined chilled packaging. It is available in three different sizes, with either a single or double layer of the Climaliner, depending on your needs.

How Macfarlane Packaging can help

With so many different packaging solutions available on the market, it may be hard to know which one is right for your product and needs.

At Macfarlane Packaging, we are here to assist you in finding the best environmentally friendly packaging solutions to help you save money, keep your products safe, protect your brand reputation and the planet.

We can also recommend ways to reduce the amount of packaging materials you use without compromising product protection. This will help minimise your environmental impact while reducing your material costs.

The post 6 Sustainable Packaging Switches: A Guide for Eco-Conscious Businesses appeared first on Macfarlane Packaging.

While bubble wrap rolls can prove a good, lightweight choice for protecting products, they have drawbacks too. They can be bulky to store and transport, consuming lots of energy to move through supply chains.

Also, due to the Plastic Packaging Tax and Extended Producer Responsibilities being introduced. This legislation is placing a positive focus on reviewing the impact of transport for bulk solutions. Many plastics face a weight-based tax, so it is logical to explore alternatives with a lower footprint.

So, what’s the solution? Enter on-demand bubble wrap. It can help reduce your material use, free up storage space and cut your transport costs and emissions. It can be a game-changer for eco and cost-conscious companies!

This article explains on-demand bubble wrap and its benefits, comparing it to traditional bubble wrap for packaging.

Understanding Bubble on Demand

First, let’s look at understanding bubble on demand…

What is on demand bubble wrap?

Bubble on demand (aka on-demand bubble wrap) is a type of inflatable air cushion packaging. It combines the protective benefits of bubble wrap with the benefits of using a more compact packaging material.

It comes on deflated, compact, and manageable rolls in boxes that can be stacked and stored anywhere in a warehouse or facility. Before packing, the material is then inflated on-demand, as and when needed.

There are lots of different on-demand bubble wrap packaging products available. One of the most popular is Sealed Air’s NewAir I. B.^® Flex. It can inflate rolls of film, as well as bubble wrap bags and specialist films like anti-static bubble wrap.

How on-demand bubble wrap works

On-demand bubble wrap is designed for use with an inflation system. The deflated film is passed through an inflation machine as and when needed.

Typically, bubble on demand inflation systems have a small footprint and can produce ambient air – there is no need for a compressed airline to be fitted.

These systems can inflate bubble at a rate of approximately 27 metres per minute and can sit neatly on a packing station or on a purpose-made stand. A winder is commonly available to create bundles that are easy to handle.

Common uses for on demand bubble wrap

Just like regular bubble wrap, you can use bubble on demand to protect a wide variety of goods.

Films with a smaller bubble are best suited to lightweight application, like wrapping jewellery, books and cosmetics. On-demand bubble films with larger bubbles are better suited to protecting heavier products or the most fragile products, like ceramics. For electronic devices using anti-static bubble on demand can provide specialist protection.  

Unpacking the Benefits of Bubble on Demand

Now you know what bubble on demand is, what about the benefits it offers? Compared to regular bubble wrap rolls, on-demand bubble wrap offers significant advantages.

Cost effectiveness of bubble on demand

One of the main advantages offered by bubble on demand is its cost effectiveness.

Initially, the rolls of film are compact to ship and store. This means you can reduce associated transport and storage costs. If you are paying per pallet space for your storage, this could make a huge difference compared to traditional bubble wrap. For example, just one pallet of Bubble Wrap® IB film is equivalent to 90 large rolls of bubble wrap, which would take up 46 square meters of space or 38 pallet spaces!

In addition, using the automated inflation machine can help you control the amount of packaging material you use. For example, the above mentioned NewAir I.B.^® Flex system can reduce excess material use by up to 50%. The knock-on effect of this is controlling how much you spend on packing material compared to regular bubble wrap.

As using bubble on-demand is a type of packaging automation, it can help you more effectively control labour costs too, as your packing will be more efficient!

Environmental impact of using bubble on demand

Not only can on-demand bubble wrap save you money, but it also has a positive environmental impact.

Unlike traditional bubble wrap, bubble on demand produces the exact amount of cushioning needed for each pack. This eliminates material use and overall packaging waste created.

Plus, the more compact material can dramatically reduce CO₂ impact of your supply chain. As mentioned above, it can take 97% fewer vehicles to deliver, which can significantly cut emissions and fuel use.

How bubble on demand can streamline your packing process

A switch to on-demand bubble packaging can also offer efficiency savings and streamline your packing processes.

It all starts during goods in handing. Traditional bubble wrap is big and bulky compared to bubble on demand. Bubble wrap, even when compressed, can take up a significant amount of space relative to its weight. Its irregular shape can also make it difficult to stack neatly and efficiently, leading to wasted space and inefficient use of transportation capacity.  This all requires extra handling and takes up time.

However, just one pallet of on-demand bubble film can give your warehouse team back a significant amount of time that they were spending unloading cumbersome rolls of bubble wrap.

On top of reducing handling, using bubble on demand is a type of packaging automation. The speedy inflation systems can deliver the protective packaging you need in seconds. This can cut pack times and help you increase the number of parcels you’re able to dispatch.

Comparing Bubble on Demand and Buying Bubble Wrap

Now we know about bubble on demand, when we consider bubble on demand vs. buying bubble wrap, how do the two compare?

• Key similarities and differences – both options provide excellent protection and cushioning for your products, so they can be used for easy wrapping and filling. The key difference between the two is their format. This impacts how you handle, transport and store the packaging, as well as your packing processes. Bubble on demand can be produced instantly in the right quantity, eliminating waste.
• Cost comparison – on face value traditional bubble wrap rolls will look cheaper. However, bubble on demand systems can offer significant savings in the long run. While the initial investment may be higher, especially for larger-scale operations, the savings across storage, transport, labour, efficiency and the environment payback quickly.
• Sustainability – when it comes to the environment, bubble on demand systems have the upper hand. The compact material can help significantly decrease your emissions and fuel usage, plus on-demand delivery helps you cut your material use, reducing packaging waste.

Conclusion

In conclusion, making the switch from buying bulk bubble wrap to bubble on demand is a smart packaging choice that can deliver valuable cost-savings, while reducing your environmental impact. The eco-friendly swap can also offer improved productivity and significant space savings.

So, if you’re looking for ways to prioritise sustainability, while keeping costs in check and protecting your products, bubble on demand could be the solution for you.

Ready to make the switch to bubble on demand? Contact us now to find out about our eco-friendly packaging options and begin safeguarding your products in a sustainable manner.

The post Why Choose Bubble On Demand vs. Bubble Wrap appeared first on Macfarlane Packaging.

With the UK Government bringing in sweeping reforms around packaging waste, it’s a good time to get your head around what packaging related regulations you should know about in 2024.

In this article, we’ll review the key pieces of packaging legislation that might impact you in 2024, if you’re a UK-based business.

What is packaging legislation?

Packaging legislation is any legal requirement or regulation that involves packaging materials. The legislation may only apply to certain businesses, depending on different criteria, such as how much packaging they produce or handle.

What packaging legislation should you be aware of in 2024?

In the UK there are four key pieces of packaging legislation to be aware of: Packaging Waste Regulations, Extended Producer Responsibilities, the UK Plastic Packaging Tax and the EU Corporate Sustainability Reporting Directive. Let’s take a look at each one…

Packaging Waste Regulations

If your business produces or uses packaging, or sells packaged goods, you may be classed as an “obligated producer” under packaging waste regulations. The regulations aim to help businesses to reduce the amount of packaging they produce, reduce how much of their packaging goes to landfill and increase the amount of their packaging waste that is recycled.

You’ll be classed as an obligated producer if:

• handled 50 tonnes of packaging materials or packaging in the previous calendar year
• have a turnover of more than £2 million a year (based on the last financial year’s accounts)

In this instance, you will need to be registered by a packaging producer by 7 April every year, meet any required recycling obligation and obtain evidence of your compliance. Your certificate of compliance then needs to be submitted by 31 January the following year. Click here to learn more.

Extended Producer Responsibilities

In addition to the standard packaging waste regulations, the UK Government has introduced Extended Producer Responsibilities (EPR). EPR legislation is a reform of historic packaging waste regulations that looks to shift the cost of household packaging waste management to producers.

Obligated businesses will have to provide even more granular information about the packaging they’re putting on to the UK market. They’ll also need to pay fees, depending on their packaging use and if the packaging is likely to end up in household waste. Fees are set to be modulated, based on the packaging material. So, for example, plastic is expected to be taxed more than paper. Even within the category of “plastics” different types of plastics will have different fees, depending on how easy they are to recycle.

To be considered in scope, the following needs to apply:

• you’ll be an individual business, subsidiary or group (but not a charity)
• you’ll have an annual turnover of £1 million or more (based on your most recent annual accounts)
• you’ll have been responsible for more than 25 tonnes of packaging in 2022
• you’ll carry out any packaging activities as defined by the Government

Different reporting and fees will then depend on if you’re a large business or a small business. Large businesses will have enhanced reporting and fee paying obligations, including paying waste management fees, scheme administrator costs, and charges to the environmental regulator.

Large businesses are defined as organisations over £2m in annual turnover and who are putting more than 50 tonnes of packaging on the UK market. Click here for more information.

UK Plastic Packaging Tax

Introduced in 2022, the UK Plastic Packaging Tax applies a levy to plastic packaging materials that contain less than 30% recycled content. Currently, the fee is £210.82 per tonne. From 1st April 2024, the tax will be applied at £217.85 per tonne. (You can learn more about the regulations here.)   

When you consider that modulated EPR fees are expected to be higher for plastic materials on top of the Plastic Packaging Tax, the Government is really incentivising businesses to high recycled content materials, more recyclable plastics or even ditch it in favour of paper-based packaging materials.

EU Corporate Sustainability Reporting Directive

‍The EU’s new Corporate Social Responsibility Reporting Directive (CSRD) requires at least 50,000 large companies within the EU, to create a report on their social and environmental impact actions from 2024 onwards.

While you might think “wait – the UK isn’t part of the EU anymore” the legislation could apply to UK businesses with strongholds in other European countries. They will apply in two scenarios:

• Listed Securities – if your company has securities listed on an EU regulated market, regardless of its location, it will fall under the scope of the CSRD reporting obligations.
• EU Net Turnover – if your company has a net turnover in the EU exceeding €150 million over the last two consecutive financial years, it will be subject to the CSRD if your company meets either of the following criteria:

1. You have an EU subsidiary with securities listed on an EU regulated market or qualifies as a large undertaking.
2. Your company operates an EU branch that has generated a net turnover exceeding €40 million in the previous financial year.

If these scenarios apply to your business, you will need to comply with the CRSD.

So, what does it mean for packaging? In essence, packaging strategies may form part of your sustainability reporting and have a direct influence on your environmental impact. You may need to consider your packaging waste data, the recyclability of your packaging and how packaging could affect your carbon footprint. Plus, you will have an obligation to report on this information. Find out more here.

Support mitigating the impact of packaging legislation in 2024

At Macfarlane Packaging, we’re geared up to help you mitigate the impact packaging legislation can have on your business:

• Sustainable packaging products – we have an extensive range of recycled content and recyclable packaging products. For example, our stock 0201 double wall cardboard boxes are made form 100% recycled content! We can also offer FSC® certified products too.
• Easy  “click-of-a-button” reporting – our e-trading system can help you produce packaging weight data in seconds, helping you cut down admin time associated with packaging legislation and waste reporting.
• Packaging optimisation – our experts can help you create more sustainable, right-size packaging that’s lighter. This can help you reduce your overall pack weight and remove CO₂ from your packaging supply chain. We can even show you the material impact of this with our unique Packaging Optimiser software that shows the cost and CO₂ reductions our solutions can generate..
• Advice from a business dedicated to sustainability – we’re always looking for ways to make our business more sustainable and help our customers do the same. We hold certifications, accreditations and standards that demonstrate our commitment to sustainability practices, like an EcoVadis gold rating, as well as being a Sedex member (find out more here). So, you can rest assured you’re getting expert packaging advice from a trustworthy source.

Don’t hesitate to get in touch to see how we can help you today.

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In this article, we’ll give you an overview of packaging automaton, the types of packaging machinery available and show you 10 decisive benefits that automated packaging can offer.

What is packaging automation?

Packaging automation is when automated tools and packaging machinery is used to increase the speed of packing alongside manual processes. It ensures consistency, reduces material waste and helps generate cost savings in the long run.

Using automated packing systems allows you to reassign valuable resource to high value tasks or in a way that better suits your operation too. You can enhance most aspects of a packaging process; from picking and packing through to conveying and wrapping, there are packaging machines for it all. 

There are semi-automated and automatic solutions available for a range of applications and businesses of different sizes.

Types of packaging automation and machinery available

You can automate almost any part of the packing process. Popular types of automated packaging include:

• Box automation – you can automate case erection and case making with case erectors, helping you get a perfectly shaped box every time!
• Bag automation – if you’re bagging product, auto bagging machines are available to speed up production, including systems that run both paper and polythene bags.
• Tape automation – rapidly sealing boxes with a case sealer that uses machine tape or a gummed paper tape machine can help you process more packs per hour. 
• Stretch automation – using semi-automated pallet wrappers is a great solution for any business using more than 15 pallets per day. Fully automated and horizontal wrappers are available for high-demand operations too!
• Strapping automation – an extensive range of banding machines are available, from handheld welding tools through to fully automated strapping machines that apply pallet banding for you.
• Protective automation – easy to install into existing packing areas, inflatable air void fill machines and paper cushioning machines can be used to keep your products safe during transit.
• Paper automation – from wrapping through to void fill and cushioning, you can choose from a wide range of paper packaging machinery to enhance your operation.
• Polythene automation – heat shrink tunnels and heat sealers can make light work of bundling and packing products!

You can also automate picking and warehouse movement with robotics and conveyor networks.

10 decisive benefits of automated packaging

So, why should you think about upgrading to automated packaging? Here are 10 decisive benefits for you to consider:

1. Improved productivity – in most lean supply chains, time is of the essence. You want to get your product packed and out the door as quickly as possible. Enter automated packaging systems.  You can speed up your pack times exponentially! For example, some case sealers and auto bagging machines can produce up to 30 packs per minute!
2. Reduced downtime – implementing packaging automation can often mean less downtime. As many packaging machines have a large capacity, your team can often reduce the time spent fetching packaging or replenishing manual workstations. 
3. Control over labour costs and allocation – improving your productivity has a knock-on effect on your labour costs and allocation. Using packaging automation allows you to cut the need for temporary labour during peak periods and reallocate permanent resource to your most high-value tasks.
4. Enhanced health and safety – as packaging automation removes manual processes, it can have a positive influence on your staff health and safety! For example, it often lowers the risk of repetitive strain injuries or accidents associated with manually adjusting packaging (e.g. cutting boxes down with knives).  
5. Lower packaging waste and improved sustainability – using automated packaging can control how much material you use – this can help you lower packaging waste and improve your overall sustainability, as your pack size will be optimised throughout your supply chain.
6. Improved packaging process quality control – packaging automation can remove the element of human error. No more over or under packing, an automated packing system will use the right amount of material every time. You’ll get consistent pack size and appearance, as well as the above-mentioned reduced packaging waste!
7. Fewer damages – the improved packaging consistency can help you reduce damages that occur during shipping too, as your packaging is optimised every time.
8. Better parcel palletisation – consistently sized packs can help improve palletisation, you may be able to get more packs on a pallet or improve your pallet strength and durability via improved stacking.
9. Lower transport costs – the optimised packaging achieved through automation can help you control transport and courier costs. You may have lighter packs, improved cubage and better palletisation, which all have a positive knock-on effect.
10. Space released in your warehouse – in addition to the above benefits, using automated packaging systems can even save you space! Many machines have compact footprints and switching to automation may allow you to condense the packaging materials you keep in your warehouse, releasing valuable space for your product.

With these 10 benefits of packaging automation in mind, now might be the time for you to consider implementing it!

Support with packaging automation in 2024

At Macfarlane Packaging, we can help you transform your operation with packaging automaton. Click here to learn more about how we can help with automation or get in touch today to book some time with our automation experts.

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Resolutions don’t just happen in our personal lives either, it’s a great time to reflect on business performance in 2023 and what improvements you could put in place to make 2024 stronger. 

In our experience, a good place to start with workplace resolutions is your packing operation. Changes there can have a positive knock-on effect throughout your business – improving efficiency, reducing cost, maximising transportation, and reducing the carbon footprint of your supply chain.

Here are eight packing operation resolutions to consider for 2024:

Create space to grow your business

If you’re fast outgrowing your warehouse or, would like to expand your operation but cannot see the way to do this without moving a new premises, then perhaps a rethink of how you are currently utilising the space may help.

Warehouse space is at a premium and forms a large part of any company overhead, but have you planned that space or, has it just evolved over time to accommodate your operation?

A rethink of your storage space may unlock opportunities to expand production or your packing area. For example, a pallet stored on the floor takes up 1.2sq metres of space, often enough area to install a pack bench.

If your looking at ways to increase your workable space, you may be interested in reading our previous blog “How to unlock warehouse space for your packing operation in 2023”, it’s an oldie but goodie.

Identify opportunities to free up cashflow

Cashflow is king, so why are you paying invoices for bulk quantities of packaging which won’t be used for months? You may get a great price from a manufacturer initially but, packaging doesn’t generate revenue. The cost of storing slow moving stock week after week is cancelling out those procurement savings.

Consider buying little and often from a packaging distributor on a stock and drip contract or JIT. You get the packaging you need, when you need it and, paying for it at point of use.

Removing pallets and pallets of slow-moving packaging stock also contributes to your first resolution of creating more space too!

Boost efficiency with an ergonomic space

Is it time to rethink the layout of your packing operation? There are so many ways you can optimise a workspace to make it more efficient and increase productivity.

Well organised, purpose-built workstations can revolutionise the packing area, reducing the amount of “wandering” around the warehouse to get the right packaging to wrap products being shipped.

They can be customised to hold the packaging you need, including different sized boxes and mailers, protective infill systems, tape dispensers and label printers. With everything you need to hand, your packing area can become a well-oiled machine. 

Pack bench height can be adjusted too, allowing you to tailor the station to the comfort of your packers, so they can either sit or stand (don’t forget an anti-fatigue mat too, to reduce the risk of pressure to feet and legs).

Consider a conveyor system interconnecting picking areas, pack stations and goods-out. Creating a seamless link in your packing operation, they can be fixed or mobile, set to the height required for your products, and be as integrated or free standing as you require.  For example, you may go with a roller conveyor to start, where you manually push the goods to the next area.  For larger more established operations, a belt driven option with light sensor activation and control can be set to automatically direct packaging to multiple locations.

Reduce the amount of packaging material you use

When less packaging is used, you are not only reducing overall waste but business costs too.  It’s a win-win situation.  This is especially important if you are working towards the new EPR legislation which will affect manufacturers, distributors, and retailers where their product packaging will end up in household waste streams.

A rethink in box size can reduce the amount of material used as well as reducing the need to void fill. 

Are there opportunities to re-engineer your packaging material to reduce the weight? 

Consider ways to reduce the weight of material you’re using each year too. For example, a switch to a stronger adhesive tape can help to reduce the overall amount you need to apply, removing the need to H tape packs.  A stretch wrap review can also unlock opportunities to reduce the amount of material needed to wrap each pallet, often a Macfarlane Packaging Stretch Wrap Review reduces material use by up to 50%.

As well as reducing material use, you will also reduce the cost of your packaging and improve the overall carbon footprint of your business.

Optimise your delivery fleet and courier network

Building on the resolution of using less packaging material, by rethinking your packaging and optimising your pack cubage you may be able to fit more goods onto a pallet or, increase your vehicle payload. 

This will drive optimisation of your delivery fleet or reduce courier costs if you’re paying by size or weight of parcels shipped.

By increasing the capacity of your delivery vehicles, you can reduce the amount of vehicles you need to load, combat driver shortages and fluctuating fuel costs.

Combat labour shortages with packaging automation

Labour shortages are a defining feature of the logistics industry, but when you use packaging that’s quick to assemble, pack and wrap, you can increase throughput and manage production spikes more efficiently with the workforce you have in place.

Bringing in a level of packaging automation can also help to support a more efficient operation, reducing menial, repetitive tasks and allowing you to upskill your workforce.

There are packaging automation solutions for every size of business, at a cost to suit every budget too.  It doesn’t need to be a huge cap-ex project.

For smaller businesses, you may consider entry level automation, like electronic gummed paper tape dispensers, which cut strips to size ready for speedy application.  Or perhaps a void fill dispenser which automatically adds the right amount of protection at the click of a foot pedal.

If you’re wrapping more than 14 pallets per day, consider a stretch wrap machine which efficiently applies film to your pallets, leaving your operators free to take the last pallet to goods out or, bring in the next pallet for wrapping.

Box erectors and sealers can assemble your packs ready for filling, so operators can focus on packing. If you want to “go large” an auto-boxing or bagging machine can be installed to build, fill and seal packs.

Automation can be as integrated as you want to make it, there are options to suit every size of business to reduce the number of touches to a product or pack, reduce manual handling and material use, as well as speed up your operation. 

Meet your sustainability targets for 2024

Carbon footprint reduction plays a key part in ESG goals, with larger businesses committed to Mandatory Greenhouse Gas Reporting by the UK Government. The race is on to make better use of natural resources.

Many of the resolutions above will help you to reduce your packaging use, optimise your delivery fleet and cut emissions from the supply chain. 

Book a packaging review with Macfarlane Packaging

So, how do the above resolutions sound? Overwhelming when you still have your regular day job to do?  Don’t worry, we can do all the above for you with a free of charge, no obligation packaging review!

We come to, walk through your operation to see what your packing, how you’re packing it and then, we suggest some solutions to help you get those resolutions in place.

Look at how Macfarlane Packaging can support your business or, contact us today to book your packaging review.

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