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.

Being one of the staples of any warehouse, it’ll be hard to find an operation that doesn’t use tape at all in their packing process. But how much do we really know about it? 

This blog will be exploring what packing tape is made from, the different types of tape and methods to apply it! We’ll cover common questions about recyclability and help you decide the best tape for your business. 

What is packing tape made from? 

Generally, packing tape is composed of 2 to 3 main parts. Here’s a short explanation of each: 

• The backing or carrier – this the physical material tape is made from. In the case of packing tape, the backing is often made from polypropylene, vinyl or kraft paper. Other more technical types might have a backing or carrier made from other materials, such as crepe paper or even cloth. 

• The adhesive – this is the stuff that makes tape stick. There are several different adhesives used for parcel tape, including acrylic, solvent, hot melt and even water-activated adhesives. 

• The liner – when it comes to packing tape, a liner is sometimes used on some pressure sensitive or double-sided tapes. It stops layers of the backing material from sticking together. 

What are the different adhesive types used on packing tape? 

Most packing tape will use one of these four adhesives: 

• Acrylic – water-based acrylic adhesive is the most popular and low-cost adhesive used on packing tape. It works in a wide range of ambient temperatures, up to 50°C. It has good resistance to discolouration and adhesive bonds it forms get stronger over time. Tapes with acrylic adhesive are primarily applied by hand. 

• Solvent – if you are looking for long-term strength, solvent-based adhesives could be great for you, as they can be stuck down with low pressure and form strong bonds. Solvent adhesives have excellent temperature tolerance, working at -4°C up to 65°C. It’s the ideal choice for cold chain environments.  

• Hot Melt – when heated, this synthetic resin becomes tacky which creates this adhesive. It is one of the strongest types of adhesive available. It has high initial tack, so is a good option when sealing at speed with electronic tape dispensers. It has a more limited temperature tolerance, so is suited to ambient packing environments.   

• Water Activated – this is a starch-based adhesive used on gummed paper tape. It needs to be moistened to activate the adhesive and it solidifies as it dries. It creates strong bonds with cardboard and can provide tamper evidence. 

Different kinds of tape dispensers & ways to apply packing tape 

• Handheld tape dispensers or tape guns – If you’re packing more than one box, you can use a handheld tape dispenser; it saves time by never losing the end! Designed for use with most self-adhesive tapes, handheld dispensers often have a built-in brake that adjust easily to accommodate varying unwinding speeds. Tape guns come in different sizes for packing tapes with different size cores, too.  

• Manual gummed paper tape dispensers – manual gummed paper tape dispensers are reliable and user-friendly. For example, our BP222 model has fifteen manually set lengths and is ideal for use where there is no convenient electrical power supply. Perfect for light to medium usage and compatible with either reinforced or non-reinforced water-activated tapes. 

• Automated tape gummed paper tape dispensers – Moisten, cut, and deliver pre-programmed lengths of gummed paper tape. Ideal for medium to high usage. 

• Automatic case sealers – for high-demand environments, a case sealer or in-line tape machine is the ideal choice. As a box goes through a case sealer, they apply pressure sensitive tape to the box. They can seal up to 30 boxes per minute, depending on the model. You can also opt for a case sealer that uses glue rather than tape.  

Packing Tape Types 

There is a wide range of different packing tape types. When you’re looking at which tape to buy, most types will be classified by the material they’re made from and the adhesive they use.  

Adhesive tape can be made with:  

• Polypropylene  

• PVC (also called vinyl)  

• Kraft paper  

• Crepe paper  

• Cloth  

• Foam  

• Foil  

The three most popular materials used for packing tape are polypropylene, PVC and paper.  

These tapes can come in lots of different variants, like reinforced tape (which contains filaments to make it stronger), tamper evident tape, low noise tape and lots more! For example, if you’re looking for the strongest tape, a reinforced tape with a solvent adhesive would be a great option.  

Common questions about packing tape 

Below we have listed some popular questions people have around packing tape. If you have any more queries that are not listed, our team of experts will be happy to help you. 

What is packing tape used for?  

Packing tape is primarily used for sealing cardboard boxes. The adhesive in packing tape forms a bond with the cardboard to prevent boxes from opening during storage or transit.  

Can packing tape be recycled? 

Whether packing tape can be recycled depends on the type you are using. Most types, such as polypropylene and PVC, are not easily recyclable in the UK. 

If you are looking for an eco-friendly option, both polyester adhesive (PET) and paper-based tapes can be recycled. Paper options come in either a self-adhesive or gummed format. 

In theory, paper tape may be recycled as part of the paper recycling process; however, UK Recycling facilities have been developed with mechanical processes that separate it from paper and card. The paper products can then be recycled, while the plastic alternatives are usually incinerated for energy recovery. 

Water activated tape is by far the most “recycle-friendly” option, as the bond it forms with cardboard means it essentially becomes “part of the box”. 

Can I have tape printed with my logo? 

Yes, we can offer a wide range of custom print options to meet various requirements. Adding a logo or message to your tape is a great, relatively inexpensive way to customise your packaging quickly and easily. 

We can also supply a range of standard printed options, such as fragile tape, as well as floor marking and masking tapes. 

Which packing tape is best? 

The kind of packing tape you need will depend on the product that you’re sealing. 

For a recommendation tailored to your packing processes and product, contact us to speak with one of our packaging experts who will help you determine the best packing tape for your requirements.  

How do I choose the right packing tape?  

Choosing the right packing tape depends on lots of different factors. You need to consider:  

• The boxes you’re packing in (different board grades can impact adhesion)  

• The weight of the product you’re packing (heavier parcels may require reinforced tape or a strong adhesive)  

• The environment you’re packing your parcels in (e.g. is it cold chain or ambient? This can impact adhesive performance)  

• How you want to apply the tape (e.g. some tapes and adhesives are better suited to machine application than others) 

• Do you need any special messages or tamper protection?  

Support with packing tape  

Macfarlane Packaging can supply an extensive range of packing tape, as well as associated machinery, like gummed paper tape dispensers and automatic case sealers. Get in touch today for tailored advice.  

The post A guide to packing tape and adhesive tape  appeared first on Macfarlane Packaging.

If you sell your product online, via your own website, Etsy or even Not on the High Street, your packaging is the first physical touchpoint in your customer journey. As there are a growing number of small businesses in the UK, it could be a great time to consider branding your small business packaging to enhance your unboxing experience and stand out from the crowd. So, where should you start?

Your first thought might be printed boxes. However, these often require high order volumes, making them unsuitable for small businesses. But don’t fret – there are still simple, quick, and effective ways you can easily brand your packaging….

Why is branding your small business packaging important?

Branding your business and your packaging is important as it can help you create a memorable impression on consumers and lets them know what to expect from your company…

Strong brands have signature colour palettes and an easily recognised tone of voice. Think about your packaging materials as an extension of your brand. Use it to create instant recognition and build brand awareness. The great impression you create when packaging lands on a customer’s doorstep can delight them and result in repeat sales too.

In 2023, our Unboxing Survey found that 57% of retailers are making the most of their packaging with branding and you could be too! Enhancing your customers experience is not just for large retailers anymore.

If you’re interested in more about consumer opinion about packaging, we are running our 9^th annual Unboxing Survey now! Learn more about it here.

Easy ways of branding your packaging

By focusing on simple but effective elements to add to your packaging, you can create an unboxing experience that sets your business apart from the competition.

Add easy personalisation with printed tape

With a minimum order quantity of only 72 rolls, custom printed tape is a great way to start branding your small business packaging. It adds a touch of personalisation without having to invest in a large quantity of packaging. Packaging you may. not need or have space for.

You can print both traditional packing tape and self-adhesive paper tape – so you don’t have to compromise on sustainability if you prefer paper packaging materials.

Due to the low order quantity, you could even consider getting creative with your brand messages during seasonal holidays. For example, adding hearts for valentines or even snowmen for Christmas!

What are the benefits of custom printed packing tape?

• Low MOQ (Minimum order quantity)
• Easy to adapt for different seasonal messages e.g., Christmas
• Great for advertising
• Cost-effective and easy to store
• Offers a sustainable alternative

Until 30^th September, we are offering FREE origination on selected tapes, on as little as 72 rolls / 2 boxes of tape! You can choose from a choice of paper, PVC and polypropylene. Request a quote by getting in touch today.

Consider custom labels

Labels are another simple yet effective method to brand your small business packaging. The possibilities are endless – you can print with your logo, your web address or even a promotional message.

Prices can vary depending on style, design, and size of the label you choose, as well as the number of colours you choose to print on it.

What are the benefits of custom printed labels?

• Easy to use
• Printed with your own design
• Small Minimum Order Quantity
• Easy to apply during the packing process
• Minimal storage space needed

Try branded tissue paper

Custom branded tissue paper is a great way to showcase your brand’s identity whilst protecting your goods. Adding this extra elements creates a sense of luxury, making the unboxing experience memorable and shareable on social media.

With so many different options when choosing tissue paper, it is a great simple solution to enhance your brands image.

What are the benefits of custom tissue paper?

• Perfect presentation for all sorts of goods
• Choose from an array of colours to suit your brand
• Acid free options, ideal for silverware and jewellery to prevent tarnishing
• Non-toxic tissue paper is available for food items
• Machine glazed tissue or matte finish tissue paper which can be interchangeable to get your ideal look

Enhance your offering with custom mailing bags

Mailing bags are a staple for shipping a variety of products in many industries. With the large array of sizes to choose from and eco-friendly options available too, mailing bags can also be customised to suit an array of packaging needs.

Custom mailing bags are an excellent way to start adding branding to your packaging. It’s a slightly larger commitment than other elements like tape, but it allows for more creativity and a memorability.

What are the benefits of custom mailing bags?

• Available in a range of sizes
• Eco-friendly options available
• Range of printing and finishing options
• Choose from a range of materials like plastic and paper mailing bags
• Great for shipping a wide range of goods

Think about when your small business grows

These simple ways to brand your small business packaging are a great start. As your business grows and your sales volumes increase, you could be ready for printed packaging that demands higher order quantities – like the boxes we mentioned before.

If you feel you need guidance about your small business packaging, the Macfarlane Packaging team are here to help.  We can help with packaging solutions for businesses of any size that protect your goods and your reputation, while creating a great customer experience.

The post Easy ways of branding your small business packaging: updated appeared first on Macfarlane Packaging.

Custom packaging extends beyond product protection and functions as a marketing tool that leaves a lasting impression on your customers. But what exactly is branded packaging? And is it right for your business?

In this blog, we will explore branded packaging and why it’s beneficial for you. We will also offer tips for a memorable unboxing experience with both custom shelf-ready packaging (SRP) and transit packaging.

What is branded packaging?

Branded packaging refers to using customised packaging designs to promote a company’s brand and create a memorable unboxing experience for customers. Consider it a strategic marketing tool that helps businesses stand out from the competition.

There are various types of branded packaging to choose from, including custom-printed boxes, bags and labels. Each pack can be tailored to reflect your unique brand identity, values and message.

Benefits of custom packaging

Enhancing brand recognition is one of the key advantages of branded packaging. When your packaging stands out with your unique branding elements, it becomes instantly recognisable to consumers.

Recognition helps create a lasting impression and increases the likelihood of customers recalling your brand when making purchasing decisions. This is especially true for shelf-ready packaging, which can use eye-catching colours or messages to be easily identifiable for new customers and memorable for returning customers.

For shipping purposes, we like to say packaging has a 100% open rate. You can’t afford to miss out on key real estate, especially when unboxing videos are so popular online. If you can use a custom-sized packaging solution that fits your product well, it will minimise your overall pack size. This has a knock-on effect across your packing operation by reducing storage and shipping costs and the likelihood of damages.

 Some key benefits of choosing custom designed packaging are:

• It helps better protect your products
• It improves your customer experience
• It can help build your brand awareness
• It contributes to your packing operation being more sustainable
• It can reduce damages and returns
• It could reduce your shipping costs

Every business is unique, but if you are considering branded packaging, our team of experts could help you find the right solution for your business.

Our Innovation Labs help you find the right pack through design and testing to bring your custom solution to life.

We also have a specialist presentation and retail packaging team who will work with you to deliver retail supplies that enhance your brand and deliver a memorable unboxing experience.

The importance of sustainability messaging

As the public is becoming more eco-conscious, utilising the touchpoints you have with customers is not only beneficial for you but also them. Using sustainable packaging that’s clearly labelled could help you make a big difference.

If you’d like to learn more about eco-friendly practises, you can download our free guide to sustainable packaging here.

Tips for creating a memorable unboxing experience

Creating a memorable unboxing experience is a powerful way to engage consumers and boost brand loyalty. Here are some tips to creating a memorable experience for your customers with both shelf ready and transit packaging.

Shelf-ready (SRP) packaging

1. Design for easy conversion: Consider creating supplier-to-retailer transit packaging that can easily convert into shelf-ready packaging. This streamlines the process for retailers and ensures your product is displayed correctly and according to your brand guidelines. Perforated edges or tear strips can facilitate easy opening.
2. Optimise for display: Ensure that once the transit packaging is opened, it can serve as an attractive display without requiring significant additional effort. For additional branding opportunities, design the outer carton to double as an in-store display case, ensuring brand visibility and easy access for consumers.
3. Consistent branding: Maintain consistent branding elements across all packaging layers. This consistency reinforces brand recognition and makes a strong impression, especially on busy store shelf.

Transit packaging

1. Ensure durability: Transit packaging must be robust enough to protect the product during transportation. Even if beautifully designed, receiving damaged goods has a negative impact on customer experience
2. Secure contents: Use custom inserts, foam padding or air cushions to secure products whilst shipping. This prevents movement and potential damage during transit. For security protection, consider tamper-evident seals.
3. Consistent branding: Maintain consistent branding elements across all packaging layers. Consistency reinforces brand recognition and makes a strong impression; this is important for transit packaging as it might be your customers first touch point with your brand.
4. Easy use and disposal: Ensure the packaging is easy to open and recycle. Include tear strips for easy opening and provide clear instructions on how to dispose of the packaging responsibly.

How Macfarlane Packaging can support you with branded packaging

At Macfarlane Packaging, we can help you with all kinds of custom packaging.

Whether you need a bespoke packaging solution to provide protection for high-value products or want to enhance your customer experience with branded packaging, our experts will be with you every step of the way!

The post The impact of branded packaging 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.

In 2023 the SMMT reported that the Automotive-related manufacturing sector in the UK was on track to reclaim it’s £100bn trading hub status by the end of the year.  In fact, the year ended with total manufacturing numbers up 17% on the previous year, with the UK producing  905,117 cars, 120.357 commerical vehicals and an estimated 1.6 million engines.  It was the industry’s best year since 2019.

Automotive-related manufacturing in the UK generates approximately £67 billion of turnover annually. The UK produced almost 860,000 cars and 1.6 million engines in 2021, as well as approximately 73,000 commercial vehicles.

And as estimates indicate that a single vehicle can have as many as 30,000 parts, ensuring you are using the correct packaging can be a significant challenge.

If you work within the automotive industry, this guide to car parts packaging provides you with a detailed overview of considerations and options. Whether you are responsible for packaging at an OEM, tier 1, tier 2 or tier 3 supplier, this article details a range of tried and trusted options that allow you to pack and ship car parts successfully.

Car parts packaging can take various forms. It can include everything from returnable containers within the supply chain to corrugated boxes used for aftermarket parts. Your packaging can be designed to improve handling, protect components in transit, and enhance the efficiency of production lines.

Considerations when packing and shipping automotive parts

Before looking at the varying types of car parts packaging, it is essential to consider several factors. The six primary considerations for car parts packaging are:

1. The weight of the product/part you are shipping
2. The fragility of the parts
3. How valuable are the items you are shipping
4. The packing and unpacking processes
5. How your parts (and packaging) are handled in the supply chain
6. Any impact on the environment

Weight of products

The weight of your parts or components is important when specifying your automotive packaging. Heavier items need more durable packaging to ensure it does not fail during transit. Lighter items should have their packaging optimised to minimise weight and reduce costs and CO2 emissions through the supply chain.

Fragility of parts

How delicate your car parts are also influences the best packaging for your business. You may require cushioning and inserts to minimise damage caused by handling in the supply chain, although even the more robust items still need protection. You should also consider protection for surface finishes on painted, polished or decorative surfaces.

How valuable are the items you are shipping

The packaging you use for shipping high-value infotainment units or gearboxes, for example, needs to be a different specification than that used for relatively cheap plastic trims or ancillaries.

Packing and unpacking processes

It is crucial to consider how quick and easy it is to pack and unpack your products. Does your car part packaging use much secondary packaging such as bags, inserts or films? Is it easy to pack multiple smaller parts in the same outer container? Are there any additional processes that packing teams need to carry out which may impact production times and efficiency?

How do transport providers handle parts during transit?

It is wise to consider how your items are handled within the supply chains. For example, are there many touchpoints that could result in mishandling? Does packaging need to look presentable at its final destination (e.g. for aftermarket parts or retail items)?

As well as how items are likely to be handled, it is also essential to consider the methods of transport and the possible environments your car parts packaging may encounter – will it be left outside or have the potential to get wet, for example?

Impact on the environment

The final consideration is the impact that your packaging has on the environment. Does it allow you to maximise transport efficiency, or are you shipping lots of empty space? Can any single-trip packaging be easily recycled by the end user? Would returnable or extendable packaging be most suitable?

Expendable vs returnable

This final point leads nicely to arguably the most important consideration for shipping car parts – whether to use expendable or returnable packaging.

But how do you decide which is best for your business?

Generally, the longer the distances involved in the logistics leg, the less practical it becomes to use returnable packaging. The vast majority of returnable automotive packaging is used within short loops and those with fixed arrival and distribution points.

Of course, you may not have reliable return transport, your parts are for use by the end consumer (hence the packaging cannot be returned), or it is not economical to return empty containers to your warehouse or manufacturing site.

Another point to consider at the outset is what different manufacturing plants or customers accept. Many do not have facilities to dispose of large volumes of single-trip packaging and only accept products in returnable packaging. Others may specify expendable packaging. It is vital to check what your customers want!

Returnable supply chain packaging

However, it is likely that, as part of an automotive supply chain, you will use returnable packaging of some description.

Due to the vast numbers of parts and overall throughput of vehicle manufacture, using returnable containers eliminates the generation of huge amounts of packaging waste compared with single-trip.

Returnable containers are typically more robust, providing better protection for parts, and are frequently industry standard sizes that allow for improved space efficiency in transport and production lines. They can also allow for safer stacking and handling.

And arguably the most crucial point, returnable packaging provides a lower cost per trip or lifetime cost than expendable packaging.

Euro containers

Euro containers are the most commonly used returnable packaging for car parts and components. Often referred to as KLT containers or ALC (attached lid containers – when including a lid), these moulded plastic boxes are available in standard sizes to be compatible with most pallets, racking, conveyors and so on.

They are both cost-effective and robust, hence their popularity and widespread use.

Correx tote boxes

The main limitation of Euro containers, however, is their standard sizing. Fixed dimensions can sometimes mean wasted space within containers when shipping unusually shaped or sized items. This issue reduces transit efficiency (you are paying to ship fresh air) and can also mean adding a large volume of void fillers or other inserts. It also reduces assembly line part density.

As a result, a returnable packaging option that is growing fast in popularity is Correx tote boxes. The key benefit is that you can opt to manufacture them in custom sizes. This size flexibility means they can accommodate unusually shaped items or a defined number of parts for a specific assembly.

Correx totes are also lighter than moulded containers, which can help reduce transit costs and emissions. And, due to a range of material options, you can select to have them manufactured with strength comparable to euro containers or tailored to the requirements of specific items.

Expendable packaging

Despite the benefits of returnable car part packaging, there are scenarios where single trip or expendable packaging would be most suitable. As well as parts that ship directly to end users, there are uses within supply chains for these options. Particularly where parts travel long distances and/or return is difficult.

Heavy duty corrugated

Many businesses use corrugated packaging within automotive supply chains. It has the same advantage as Correx in that it allows for the production of custom-sized boxes. Bespoke sizing enables the benefits of space efficiency, lower transit costs, emissions etc.

Several heavy-duty material grades can provide surprising durability, including various double and even triple-wall materials.

Other benefits include easy printing of handling and other instructions directly onto the packs and, of course, cardboards’ ease of recycling.

Timber crates and cases

Timber crates are another option in certain parts of automotive supply chains. Like corrugated, they can be easily produced in bespoke sizes to accommodate specific parts. They are particularly suited to shipping larger panels, assemblies or even engine blocks.

Whilst they can offer some reusability, they are also more challenging to dispose of and more costly than cardboard equivalents.

Dunnage and inserts

Whether you use returnable or single-trip packaging to ship your car parts, you can enhance the performance and efficiency using dunnage – effectively different forms of inserts.

Inserts can allow for much-improved part density within an outer container and make packing and unpacking quicker and easier. Inserts also help minimise damage as they limit movement and prevent parts from colliding with each other. Inserts can also provide precise positioning of components to allow for robotic assembly.

Divisions

Simple divider sets manufactured using Correx or even cardboard can provide all of the benefits mentioned earlier. Usually created to suit a specific product or assembly process, you can choose the cell size and configuration (e.g. 4 x 4 cells within the container). Dividers can be removable and folded flat or integral to the construction of Correx totes or trays.

Textile dividers

Some parts – for example, interior fittings or painted parts – have decorative surfaces that customers can reject due to surface scuffs or marring. If this is a concern, using a material such as Bubble-board can eliminate this. The plastic material is laminated with spun-bond fabric to protect from scratches or foam to provide additional cushioning during shipment.

Custom inserts

For unusually shaped parts, custom fittings can provide a perfect fit for the item in question.

Vacuum-formed trays

Vacuum-formed trays are another option widely used to handle car parts and components. They have recesses moulded to the exact shape of the items they carry to provide protection and ease of packing/unpacking.

Foam

Finally, you can use various foam inserts for particularly delicate or high-value items. As per vacuum-formed trays, foam inserts can precisely match the contours of any part or component. They go a step further, however, in that they also provide excellent cushioning protection.

Specialist software even allows for the optimum level of protection to be engineered into the foam packaging – crucial for high-end parts that cost thousands of pounds.

Airsac cushioning protection

An inflatable packaging solution which moulds itself to your products, Airsac can be used on small automotive components or larger body panels for vehicles, such as doors and bonnets.  

Airsac utilises pockets of air to provide high levels of protection, making it extremely light and easy to handle. Available in a range of formats, such as a full bag or end cap, it can be used to replace traditional cushioning products like foam or stratocell.

As it’s inflated on demand, Airsac is an excellent way to remove bulky packaging from the packing process and free up storage space on site.

Protecting car electronics

As technology advances, more and more aspects of new vehicles rely on electronics and microchips. Everything from telematics, navigation, driver assistance systems and even infotainment units rely on increasingly sophisticated technologies.

But these parts and components can be susceptible to a different form of damage – electrostatic discharge (ESD).

What is ESD?

ESD is the transfer of an electrical charge between two objects. Whilst this occurs naturally, the heat generated during this process can cause significant damage to microchips and electronics. And whilst the effects may not be immediately apparent, latent damage can result in performance degradation and decreased lifespan of items that rely on electronics to function.

Conductive packaging options

Due to this, several anti-static and conductive packaging products are commonplace in automotive industries.

Corstat – a corrugated cardboard with a carbon coating – creates a “faraday cage” effect. This essentially channels any static around the outside of the packaging, protecting any items within.

Plastic options, including Corriplast conductive Correx and moulded plastics, operate similarly, whilst various ESD-safe foams are also available.

Other specialist car parts packaging

Several other specialist packaging applications are common within the automotive manufacturing industry.

VCI protection

A volatile corrosion inhibitor (VCI) is a material that protects metals from corrosion (i.e. rust). Vehicles use a considerable amount of metal components, so shipping these over long distances has the potential for this type of damage to occur.

Numerous VCI papers and bags are available to pack components in, whilst others may be coated in grease or similar substances to protect them during shipping. However, all these add another process to packing and unpacking operations.

An alternative is to coat your packaging with a VCI material, which can provide an equivalent level of protection.

Scuff protection

As mentioned earlier, inserts and dividers can be manufactured using material that prevents surface scuffing and marring. These properties are essential for painted, polished or coated parts or those which form part of the interior of a vehicle.

What is less well known is that cardboard can be surprisingly abrasive, although again, there are coatings for corrugated boxes that can help to minimise this.

Lithium batteries

A new challenge facing automotive manufacturers and parts suppliers is lithium batteries. Prevalent in electric vehicles, the UN classifies li-on batteries as hazardous goods. This classification requires specialist packaging that meets defined regulations (UN3480) to ship.

Options for this include returnable aluminium cases with specialist inserts that contain fires should batteries fail or malfunction during transportation.

Spares, eCommerce and retail

Of course, not all businesses in the automotive sector supply parts used directly in the manufacture of new vehicles. Many provide spares and aftermarket parts that go straight to service centres, garages and even consumers.

In fact, the aftermarket industry in the UK accounts for £21.1 billion in turnover each year.

The packaging required for shipping these car parts faces different challenges. Firstly, it tends to be a single trip as there is no easy option for returning it. Being expendable means considerations surrounding recyclability must be balanced against ensuring it performs well within courier and postal networks and the multiple touchpoints these comprise.

In some instances, there may even be a requirement to add branding, instructions and other information, as some parts may be displayed within retail stores or be required to provide some form of limited “unboxing” experience.

As such, businesses typically use corrugated packaging for applications of this type.

Summary

Whether you work for an OEM, or a tier 1, 2 or 3 supplier, a team of packaging experts at GWP and Macfarlane Packaging is on hand to ensure you select the most suitable car parts packaging for your specific application.

Get in touch today for advice and guidance on sourcing the optimum packaging for your business.

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