If you’re an online retailer, the packaging you use can be a make-or-break factor in the success of your Black Friday operation.

In this article, we’ll look at exploring Black Friday, the critical role played by packaging and 10 tips to help get your packaging Black Friday ready.

Understanding Black Friday

What is Black Friday?

Black Friday is the Friday after Thanksgiving in the United States. Traditionally, huge sales are held that mark the start of the Christmas shopping season. The term “Black Friday” has been associated with retailers since the 1950s, with the practice of Black Friday sales cementing themselves in the 1980s. The retail sale moniker is inspired by the fact that many retailers saw it as a pivotal day in the year when their operations became profitable – going from being “in the red” to being “in the black”.  

Since the 1990s, these discounted sales have taken place both offline and online.

The tradition has migrated across the pond to the UK and Ireland, and Black Friday now represents the peak season for retailers. Sales often start days or weeks in advance and extend to Cyber Monday, traditionally the Monday after Thanksgiving.  Some retailers now call this “Black Friday Week”.

The importance of Black Friday in UK retail

So, how significant is Black Friday in UK retail?

According to Mintel, in 2023, total sales during Black Friday were an estimated £13.3billion. To put this in context, in a single day, it accounted for just over 3% of all UK retail sales during 2023!

The IMRG highlights that this is one of the key selling points of the year for online retailers, with 81% of retailers reporting they make more revenue when they hold longer sale periods.

In essence, all these facts highlight the importance of Black Friday in UK retail. Therefore, it’s critical for retailers to streamline Black Friday or peak operations to achieve peak success.

How packaging plays a role in Black Friday

If you’re an online retailer, the packaging you use plays a critical role in successfully shipping your products to consumers. On the surface, packaging’s primary purpose is to get goods from A to B – a no-brainer, right?

In fact, packaging can impact so many touchpoints in your supply chain, it can influence everything from product damages and returns through to efficient dispatch, storage and even your courier fees and labour costs.

Packaging that’s difficult to assemble will slow down throughput (particularly if you’ve got temporary staff). If you’re keeping too much packaging stock in your warehouse, you could be wasting valuable space to store your product. Packing materials that are too big or too small for your products? You could be facing increased returns, reverse logistics costs and costly replacements.

Simply put, the packaging materials you use and the packing process you employ can drastically impact the success of your Black Friday operations.

With this in mind, how can you get your packaging Black Friday ready?

10 tips to prepare your Black Friday packaging

1. Review packaging forecasts

Preparing what packaging you need, as early as possible, is a high priority.

Assess your current packaging supplies and identify what you’ll need to meet the expected demand. Preparing forecasts now will help you ensure continuity of supply throughout the busy season.

2. Pre-order your Black Friday packaging  

Running out of packaging materials on Black Friday can lead to delays and disappointed customers. Once you’ve got your stock forecast, you can pre-order your packaging essentials like postal boxes, packing tapes and void fill.

Ordering in bulk can offer cost savings, and early ordering can help you avoid longer supply lead times that will come into play as demand increases closer to peak. However, you might not want to have all your packaging materials in one go. Taking advantage of a stock and drip service or  Just-In-Time (JIT) production can help you minimise stockholding, save space and protect cash flow.

3. Optimise your packaging processes

Reviewing your current packaging process can help identify inefficiencies and bottlenecks.

This can include an end-to-end view from picking through to pack bench organisation and how packaging is assembled and then sent on to dispatch. Even small adjustments can significantly speed up your packing process. For example, you can use a “water-spider” method to re-stock packing benches. This is where one member of your team replenishes workstations, so packing operatives do not need downtime to fetch additional packing materials.

If dispensing packaging speedily is an issue, you could also consider installing some quick packaging automation solutions for further productivity gains.

4. Check the quality of your packaging materials

Is your packaging optimised?

Quality packaging that is fit for purpose is vital to protect your products and provide operational efficiency. Ask yourself:

• Is the packaging quick and easy to assemble?
• Is the packaging too big or too small for any products?
• Does your packaging meet with any regulations, size or cubage requirements for your couriers?
• Does your packaging reflect your brand?
• Does the packaging provide sufficient protection?
• Do customers ever complain packaging is wasteful?
• Can the packaging be recycled?

Choosing robust, high-quality packaging materials that fulfil these criteria can help your overall efficiency and cost-effectiveness. A packaging review or using a tool like our Packaging Optimiser can help you assess your packaging quality.

5. Consider custom packaging for maximum impact

Not all packaging is made the same.

Opting for custom packaging for Black Friday can tailor a packaging solution to your exact requirements. This can be ensuring it’s the right size for your products or branding it so you stand out from the competition.

For example, branded boxes, tape, or even printed tissue paper can enhance the unboxing experience for your customers. This not only adds a personal touch but also helps increase brand recognition.

6. Preparing for returns

In an ideal world, your Black Friday deliveries will all get there in one piece and not be returned. However, there is a big trend among consumers for returning items, even when they’re not damaged. On top of this, the peak season means more packages in the courier networks, increased pressure and often, increased damages.

Make sure your return process is as smooth as your delivery process. Using packaging that is easy to return is helpful and more sustainable. A mailing bag or shipping box with an extra peel and stick strip, is an easy way to facilitate a hassle-free returns.

7. Assess if your Black Friday packaging is eco-friendly

How easy your packaging is to recycle can impact your end-customer experience.

Consumers are increasingly eco-conscious, with 20% reporting that they will not buy from a retailer who uses non-sustainable packaging. Therefore, assessing if your Black Friday packaging is eco-friendly is a good way to prepare. Providing clear recycling instructions can also reduce waste and lower your environmental impact.

8. Train your team for packaging success

Your packing team plays a crucial role in ensuring orders are packed efficiently and accurately.

Providing refresher training to permanent colleagues and packing guidelines to temporary staff can lead to packaging success. Using the right materials and processes will reduce waste, lower pack times and help you get more shipments out the door.

9. Test your Black Friday packaging

Before the big day, test your packaging solutions to ensure they perform well under pressure.

Pack and ship a few trial orders to check that your postal boxes, mailing bags and void fill are up to the task. This can help you identify any potential issues before they impact your customers.

Another great way to do this is to perform some “mystery shopping” orders to see how your packaging fares during courier networks.

10. Plan for the unexpected

Even with the best preparation, unexpected challenges can arise.

Putting a contingency plan in place to deal with potential issues, such as running out of packaging materials, can help mitigate risks. For example, if you use custom packaging, it might work to assess if a packaging supplier’s stock range has similar sizes so you can order them in an emergency.

Support getting your packaging Black Friday ready

Black Friday is an exciting but demanding time. Getting your packaging Black Friday ready can help you enjoy a successful peak period.

At Macfarlane Packaging, our team of experts are here to help you prepare your packaging for peak. From our Innovation Labs which can provide e-pass testing and packaging design through to our account managers, who can work with you on stock forecasts and offer packaging reviews, Macfarlane Packaging has got you covered. Get in touch today.

The post 10 tips to prepare your Black Friday packaging 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.

The post How to prepare your warehouse for peak season appeared first on Macfarlane Packaging.

If you are an internet retailer, you will be no stranger to the challenges that peak seasons bring.

During busy times like holidays or promotions, being able to process orders quickly is crucial for your business’s success. One of the critical components of managing this surge is your packaging process. This is where quick-install packaging machinery comes into play.

One way to streamline the packing process and boost efficiency is by implementing packaging automation. Fully integrated packaging automation takes a lot of time and planning. What we are focusing on in this article are quick and easy semi-automatic installations that are plug and play – simply set up where needed and remove some of the manual interventions needed when packing your products. The machines we will discuss will help make your operation more efficient and getting your shipments out of the door quickly during the busiest quarter of the year.

Quick-install packaging machinery provides an ideal solution for businesses looking to streamline their operations without the downtime associated with traditional fully integrated packaging automation and systems.

In this blog, we will focus on three key types of packaging automation that are easy to install, along with the benefits of each.  We also provide a checklist to help you prepare your business for automation.

Why choose packaging automation for e-commerce?

Automating your packaging processes can significantly enhance your packing operations.

One of the primary benefits of automated packaging systems is the cost savings and efficiency improvements they bring. Automation reduces labour costs and minimises human errors. Machines handle high order volumes, ensuring quick and accurate packaging, even during peak periods.

Automated packaging systems streamline order processing and packaging applications, enabling you to meet tight delivery deadlines. Improved turnaround times exceed customer expectations, resulting in positive reviews and repeat business.

What is the difference between semi-automatic and fully automatic systems?

Packaging automation is available with semi-automatic or fully automatic capabilities, which determines how much manual intervention is required by operators.

Semi-automatic systems involve a part-manual and part-automated process. For example, a box may be assembled and packed by the operator, but the machine will seal the pack.

A fully automatic packaging system will complete the task from start to finish. For example, assembling a box, adding void fill then sealing.

1. Box sealing

There are a few options available to ramp up the automatic sealing of your parcels.  Manually applying tape to your boxes can take up to 60% of your overall packing time when using traditional shipper cartons. 

The entry level quick-install step is to switch to a programmable electronic tape dispenser and water-activated tape.  These produce ready-cut lengths of tape at the touch of a button, removing the need to apply and tear the tape with a manual handheld dispenser.  Electronic Water activated tape dispensers are available either in a static workbench format, like the BP555 or, an on-the-go handheld device that can be used throughout the warehouse, like the Grip Taper. 

It’s worth noting that water-activated tape forms a stronger bond with corrugated material too. Therefore, the finished box is tamper-evident and easily recycled!

Some benefits of automated case sealers are:

Speed: Speeds up the sealing process by up to 60%.

Material savings: Dispenses the exact amount needed each time, reducing cost and material waste.

Versatility: Programmable so it can be configured to your in-house box range.

2. Void fill systems

Automated void fill systems use air pillows or paper to protect products during shipping by filling empty spaces in packaging. These are perfect for businesses that ship delicate or oddly shaped items and want to make sure they arrive safely.

Void fill systems for airbags are available with a small footprint, so they can be easily installed on a pack bench to dispense void fill materials at the touch of a button – or foot pedal.  Systems like the Mini Pak’r® or Pro Pak’R® offer recycled content airbag film too – so it’s a win for you and the environment.

Paper systems can be desk mounted or, height adjusted to stand behind the pack bench, this means it can dispense void fill materials directly into the box.  A good example of this in action are the Ranpak FillPak® systems.

Some benefits of automated void fill systems are:

Damage Reduction: Minimises product movement within the box, reducing the risk of damage.

Speed: Quickly fills voids, keeping the packaging process fast and efficient.

Material Savings: Optimises the amount of filler used, reducing waste and costs.

3. Pallet wrapper machines

Semi-automatic stretch wrap machines wrap products or pallets in stretch film to secure them for shipping. They are perfect for retailers who ship large amounts of goods on pallets to distribution centres or even direct to customers.

The system wraps the pallet automatically, leaving the operator free to prepare the next pallet for wrapping.

The benefits of an automated stretch wrapper are:

Stability: Provides additional stability to pallets, reducing the risk of products shifting or falling during transit.

Protection: Offers a layer of protection against dust, dirt, and moisture.

Efficiency: Reduces the amount of stretch film used, limiting material costs and waste.

How to select and install the best packaging automation for your business

To maximise the benefits of quick-install packaging machinery, we have pulled together a short checklist to ensure installation success.

1. Assess your current packaging process:

Identify bottlenecks and areas where automation can provide the most benefits. Consider factors such as packaging volume, product types, and available space.

2. Choose the right machinery:

Select machinery that fits your specific needs. Consider the types of products you package, the volume of orders, and the layout of your packaging area.

3. Plan the installation:

For quick-install machinery, planning is minimal. However, if you want to install more integrated systems, you will need to develop a detailed plan.  This should include timelines, responsibilities, and contingency plans to address potential issues.

4. Train your staff:

Make sure your team knows how to operate the new machinery. This training should cover setup, operation, maintenance, and troubleshooting.

5. Test and optimise:

After installation, run tests to ensure the machinery is functioning correctly. Monitor performance and make any necessary adjustments to optimise efficiency.

Quick-install packaging machinery offers internet retailers a powerful tool to prepare for peak seasons. These machines can enhance your packaging operations by increasing efficiency and quality. They can help you meet higher demand without compromising customer satisfaction. The machines are capable of quickly expanding and improving your packaging processes.

At Macfarlane Packaging, we can help you to identify and install the right packaging automation to improve efficiency. Contact us today!

The post 3 quick-install packaging automation systems for ecommerce appeared first on Macfarlane Packaging.

This has left many companies struggling to recruit and retain warehouse operatives against a backdrop of rising wage costs.

An efficient supply chain is reliant on warehouse staff to keep goods moving. Currently, many logistics operations are challenged to recruit a team of people to make that magic happen.

Businesses must find ways to address the labour shortage in a competitive job market. This is necessary to keep their logistics running smoothly. Packaging automation could be one such solution to help ease the tension of these labour shortages.

Why does the UK logistics industry have a labour shortage?

The UK has been going through changes in recent years, especially after Brexit. This has affected the logistics industry, which traditionally depended heavily on workers from the EU. During the Covid years, older workers, across many industries, made life-changing decisions to retire early. These factors have narrowed the pool of skilled labour available to employers.

The impact of labour shortages on warehouse operations

Businesses are offering higher wages to attract and retain warehouse staff. This is because there is a shortage of workers in the competitive labour market, driving up business costs and impacting margin.

If there are no staff available, it will affect how quickly products can be picked, packed and shipped out. This can lead to supply chain disruptions, delayed shipments and strained customer relationships. This may cause current team members to work extra hours, leading to mistakes, health and safety problems and damage to products.

What is packaging automation?

Packaging automation is a system which applies packaging consistently, with minimal operator intervention. There are machines that can tape, wrap, box, and bag items automatically, making the process easier and more efficient.

Automated packaging systems are ideal for high demand packing environments where speed and efficiency are key. If you’re shipping a range of differently shaped products in significant volume, the right packaging machinery and processes can help you to optimise your operation, cut costs and future-proof your production line for growth.

How packaging automation can help

Packaging automation offers an opportunity to reduce the challenges of labour shortages, supporting packing efficiency and enabling businesses to remain competitive. Packaging automation will:

Increase Efficiency and Productivity – as systems speed up the application of packaging. They can pack, seal, label and wrap products at high speed, quickly and accurately offering a consistent packing time.

Reduce Costs – through consistent packaging application, minimising material use as well as freeing up packers to do more useful tasks. For example, a stretch wrap machine will apply less stretch wrap with consistent tension, reduce packing time and free up the warehouse operator to go and fetch the next pallet to wrap.

As automated packaging systems use so much less material, return on investment can be a matter of weeks or months, depending on the initial outlay.

Reduce Damages and Returns – as packaging material is applied consistently and to a high standard, it reduces incidents of over and under packing and the potential of damages in transit.

Reduce Health and Safety Incidents – as warehouse operative tasks are often repetitive, packaging automation reduces pulls, strains and overstretching incidents as the machine completes the packing process.

Manage Spikes in Demand – as automated packaging solutions can be scaled up or down as appropriate. This reduces the challenges of hiring and training temporary staff during Peak season.

Types of packaging automation available

Packaging automation can take on a variety of forms, depending on your requirements.

A semi-automatic process is part manual and part automated. For example, an operator may start the process, but an automated packing system will finish it. This is typically a cheaper option if you are looking to introduce some automation but are working with a budget constraint.

A fully automatic packing process is programmed from the beginning to completion. This can include everything from picking, packaging application and palletisation for dispatch.

There are packaging automation solutions available for box building, tape application, holding product in place, void filling, bagging, strapping and applying stretch wrap.

Key considerations for implementing packaging automation

There is a range of solutions available for packaging automation from semi-automatic to fully automatic and integrated systems. The best choice for your business will be dependant on your business goals, the types of products you are packing and the size of your operation.

Before purchasing machinery, talk to a packaging automation expert who can help you determine how automation can benefit your operation and increase efficiency.

They can evaluate your warehouse layout and suggest ways to improve space, increase capacity, and efficiency. They can also help you to calculate a return on investment based on operating hours and packaging use. Often large investments in machinery can be daunting, however, there are rental schemes available for some systems.

By using packaging automation, your team can focus on more important tasks instead of repetitive ones.

Regular maintenance of automated systems is important to ensure they can operate at peak efficiency.

The UK logistics industry are facing a challenging labour shortage. However, using packaging automation can help improve operational efficiency, reduce costs, and minimise the use of packaging materials. This can help businesses succeed in the competitive job market and prepare for growth and seasonal increases in demand.

Learn more about packaging automation and available solutions by downloading our guide. It will help you find the best solution for your operation and reduce total cost. 

At Macfarlane Packaging, we help customers reduce costs and increase the efficiency of their packing operations through the successful integration of packaging automation. Contact us today to learn how we can help your business.

The post Managing labour shortages in logistic operations appeared first on Macfarlane Packaging.

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.

So, have you ever considered using a case erector? Also called a carton erector or auto carton erector, these advanced machines can improve how you deal with your cardboard boxes.

This article will explain what a case erector is. It will also discuss the various types of case erecting machines. Additionally, it will explain the benefits of using one in your production line.

What is a case erector?

A case erector is a type of packaging machinery designed to automatically erect and seal corrugated cardboard boxes. They can simplify the packing process and significantly improve productivity, especially when used alongside other packaging automation.

Also known as carton erectors, these machines efficiently erect various box sizes and styles (depending on the machine selected). They offer a versatile solution for businesses with diverse packaging needs.

Do not confuse case erectors with case sealers, machines that seal boxes with either packing tape or glue.

Types of case erectors

There are several different types of case and carton erectors available on the market. We separate them into three broad categories:

Semi-automatic case erectors

Semi-automatic carton erectors will automate part of your box erection. They require some manual intervention, typically in loading flat boxes into the system. Once loaded, the case erector automates the process of erecting and sealing the boxes.

Often, semi-automatic carton erectors can be a good first step for box automation. They can sometimes be used as a stand-alone machine, to help with easy packing, or paired with a case sealer.

Automatic case erectors

Fully automated, this type of carton erector performs the entire box assembly process without the need for manual input. Automated carton erectors often offer case sealers that can use glue or tape. They are highly efficient, reducing labour requirements and increasing overall productivity.

This type of erector is good for higher-demand environments. You can modify many high-spec automated carton erectors to suit operational requirements too.

See one of the models Macfarlane can supply in action

Random case erectors

Random carton erectors handle a variety of box sizes without needing adjustments. This type of erector is ideal for businesses dealing with a diverse range of products.

Both standard carton erectors and random carton erectors work with pre-formed corrugated cardboard boxes. For example, a FEFCO 0201 style box. Random carton erectors can erect different size and shape boxes.

 Right-size carton systems

In addition to the erectors mentioned, it’s also worth noting right-size carton systems. While they are technically not case erectors, they are a type of packaging automation associated with boxes.

A right-size carton system essentially builds the right-size box for a product. This can be from a continuous fanfold of corrugated material or tray style boxes that are reduced in height before a lid is glued on. They are also known as void-reduction systems, as they minimise the amount of empty space in the finished pack.

So, which type of case erector is best?

There are many different brands of case erectors on the market. The type of case erector that will be right for you will depend on several factors, such as what you’re packing and shipping, product weight, how the package will be stored and shipped, as well as your production environment.

Consulting with a packaging automation expert before investing in machinery like this is always worth it. It can help you choose a case erector that will deliver what you need for your business.

Depending on your business maturity, you might be ready for a case erector now. Alternatively, you might consider an interim solution like a box erecting frame before you progress to machinery. This video highlights signs you’re ready for packaging automation.

6 ways you can benefit from a case erector

Now you know what a case erector is and the different types available, how can a case erector benefit you? Here are six ways your business can benefit from a case erector:  

1. Speed and Efficiency

Automatic carton erectors drastically reduce the time and effort required for box assembly. Some models offer a 233% productivity increase compared to manual processes. Case erecting machines erect and seal boxes at a much faster rate than manual methods. This significantly boosts overall productivity.

2. Precision and Consistency

Manual processes come with the risk of human error. Case erectors ensure precise and consistent results when assembling cardboard boxes. This leads to improved product protection during transit and enhances the overall quality of your packaging. Plus, if you’re palletising your product, case erectors can provide square cases every time, which means they’re easier to stack as well.

3. Environmental Impact

The precision and consistency associated with a case erector can also reduce your environmental impact. Erectors eliminate waste that human error can produce, resulting in less waste to recycle or dispose of.

In addition, square cases every time can help manage your parcel cubage minimising CO₂ emissions during transport. Another eco-friendly benefit is reducing damages in transit. This is because it cuts out the potential emissions (and cost) associated with reverse logistics.

4. Enhanced Workplace Safety

Many manual processes, such as box assembly, packing and sealing, can lead to repetitive strain injuries and staff fatigue. By automating the box erecting process, case erectors contribute to a safer working environment by minimising physical strain on your team.

5. Improved Brand Image

Consistently well-packaged products contribute to a positive brand image. Using a case erector ensures that your boxes are neatly and professionally assembled – reflecting your brand image. This can be particularly important in the online retail sector, where packaging is often the first physical touchpoint with a business!  

6. Cost Savings

When you think about investing in a case erector (or any packaging machinery) cost savings might not be the first thing that comes to mind! However, while the initial investment in a case erector may seem substantial, the long-term cost savings are significant.

Due to the efficiencies offered by a case erector, you can reduce labour costs, including the need for temporary labour during peak times. Plus, you can often reduce the amount of packing material you’re using, which results in further savings.

In addition, your production throughout put can increase significantly, helping you keep up as your business grows. Ultimately, you can enjoy a more cost-effective packing process.

Summary

Introducing a case erector into your packaging line is an intelligent move that can pay dividends. Opting for automation will help you move towards efficiency, cost savings, and improved packing quality. If you leverage packaging automation, you will be better positioned to thrive in the competitive landscape and future-proof your packing operation.

So, if you need help with a case erector (or any packaging machinery), please speak with one of our experts today.

The post 6 ways you can benefit from a case erector appeared first on Macfarlane Packaging.

If you would like to increase productivity and shorten the time it takes to deliver products to customers, automated packaging systems and processes might be the answer.

With so many options available, you may be wondering which solution is the best for your operations. Don’t worry, we’ve got you covered!

In this blog article, we will define packaging automation, explore different types available and look at some of the key advantages and frequently asked questions related to packaging automation. Continue reading to find out more.

Packaging automation – what exactly is it?

Packaging automation entails introducing automated equipment and machinery into your packing operation to accelerate the packing process.

This helps to assure consistency, avoid material waste, and save money in the long run. It also enables you to reallocate valuable resources to high-value jobs or in the most efficient method for your operation. Most areas of the packaging process can be improved by introducing automated packaging systems; from picking and packing to conveying and wrapping, there are packaging machines for it all. 

What are the different types of packaging automation?

Erecting boxes, taping cartons, and wrapping pallets for shipment can all be automated. We distinguish between semi-automated and automated packing methods:

• A semi-automated packing process combines both human involvement with elements of automation. For example, an operator can start the process, but an automatic packing system will finish it. If you want to use automation but have a restricted budget, this is usually the most cost-effective option.
• An automated packing process is pre-programmed from start to end. It can handle everything from picking products, and packaging to palletising for shipping. This option is a good solution for operations where demand is high or that predict significant grow.  

We distinguish between the following automation solutions, based on the product you’re using:

• Box automation – including solutions, such as case and box erectors, fully and semi-automated auto boxing machines as well as void reduction systems
• Tape automation – e.g. semi and fully automatic tape dispensers, in-line taping machines and carton sealers
• Bag automation – e.g. automated bagging machines and bulk bagging equipment
• Protective automation – including semi and fully automated void fill machines, air cushioning and air pillow machines
• Paper automation – e.g. paper wrapping equipment, paper void fill machines and paper cushioning systems
• Strapping automation – solutions such as: semi and fully automated strapping machines, friction welders, battery powered strapping tools and banding tables  
• Stretch automation – e.g. fully and semi-automatic pallet wrappers, vertical and horizonal stretch wrapping machinesand rotating arm stretch wrap machines
• Polythene automation – e.g. shrink-wrapping machines,heat shrink tunnels, heat sealers, impulse heat sealers and vacuum packing machines
• Auxiliary equipment – solutions, such as: automated labelling equipment, case stackers, sorters, palletisers and conveyor systems

Key benefits of packaging automation

Packaging automation offers many benefits. It can help you to:

• Boost productivity, allowing you to pack more parcels in less time
• Save space, using fewer packaging SKUs and, therefore, saving storage space before parcels are packed (less packaging stored on site), as well as cubage, which saves transport space.
• Lower operating costs, resulting in savings on labour, storage, transportation, packing materials, and productivity
• Streamline workflow, ensuring your packaging process runs as smoothly as possible
• Reduce volume handling, relieving operational strain and helping better manage spikes in demand
• Assure pack optimisation and consistency, ensuring that the appropriate quantity and type of packaging is used every time
• Minimise material waste, making sure you only use the right amount of material required to protect your product during transit and avoiding overpacking
• Reduce transport and fuel costs, enabling you to pack more products onto a pallet. This will also help reduce your carbon footprint, as less fuel means fewer CO₂ emissions.
• Ensure customer satisfaction,providing smart, beautifully packaged parcelsthat arrive with your customers damage-free
• Future-proof for growth and demand, increasing your capacity and helping control costs as your business grows.  

Read our latest blog post – Automated packaging: 10 decisive benefits – to find out more about various benefits that comes with packaging automation.

Frequently asked questions about packaging automation

Below are some of the most frequently asked questions about packaging automation solutions, along with our answers. If there’s something you would like to learn more about that we haven’t covered below, please get in touch.

How do I automate my packing process?

There are many ways to automate your packing process. You can automate almost any part of it, but if you need pointers of where to start, you will need to review your packing operation first. This will help you identify any bottlenecks or processes that could be improved or automated.

Some of the common bottlenecks include:

• Picking accuracy – miss-picks can be a sign that something isn’t working or that capacity is being outstripped by demand.
• Packing times – have packing times met targets? Are packers taking longer to process orders? During high-pressure times, packing times can be a bottleneck if processes aren’t efficient and packing materials aren’t easy.
• Dispatch lead times – do your dispatch lead times keep increasing and getting longer? This can be in response to high demand, but it can also suggest that processes need to change.
• Damages – are customers reporting an increase in damages? This can be an indicator that packing isn’t being completed properly or that the packing materials being used aren’t sufficient. 

How to choose the right packaging machine equipment?

The type of automation solution you need will depend on your products, processes, productivity goals and space in your warehouse. You will also need to factor in your budget.

There are lots of different types of packaging machinery available, from cardboard box and case erectors and auto-bagging machines through to pallet wrappers, heat shrink tunnels, in-line taping machines and many more!

What will packaging automation cost me?

Packaging automation can be an investment, depending on the solution you’re looking at. There may be a large upfront cost to purchase an automated packaging system, but the money you’ll save elsewhere in your operation will counterbalance this in the long run.

Not every system requires an initial outlay – many are available for rental or can be purchased through finance agreements. A free trial is available on many machines, which gives you the opportunity to test if the solution is right for your business. Plus, there are some cost-effective automation options out there, such as water-activated gummed paper tape dispensers. You can also opt for semi-automatic machines that can be found at a lower price point.

How do I calculate return on investment (ROI) for packaging automation?

The ROI for packaging automation is calculated by comparing the costs associated with implementing automation to the benefits it brings, including cost savings and increased productivity.

When calculating the cost of automation for your business, there are several factors to consider, including your initial investment, equipment costs, installation setup fees, staff training, and any projected long-term costs, such as maintenance and repair. Then, think about how much money you can save each year with packaging automation. This can include reducing labour costs, increasing productivity and throughput, reducing material waste, as well as improving product quality and consistency.

How do I futureproof the investment in packaging automation?

When you invest in packaging automation, it’s important to make strategic decisions and put processes in place to keep your packaging automated system running smoothly and up to date with the latest technologies and industry developments. Consider things such as regular and preventative maintenance, staff training, periodic calibration and testing of equipment as well as spare parts inventory.

Why choose Macfarlane as your automation partner?

At Macfarlane Packaging, we work closely with our customers on a case-by-case basis to find the best automated packaging solutions for their requirements.

We can offer a wide choice of automated packaging solutions to fit various demands and budgets, whether you need a pallet wrapper, water activated tape dispenser, carton sealer, case erector, or anything in between.

Contact us today to go over your packaging needs.

The post Packaging automation: a quick guide    appeared first on Macfarlane Packaging.

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.

The post Automated packaging: 10 decisive benefits appeared first on Macfarlane Packaging.

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.

The post 8 packing operation resolutions for 2024 appeared first on Macfarlane Packaging.