The online butchers market are set to rise too, with a predicted market share of 11.2% by 2027, which will account for £1 in every £9 spent on grocery.

We’re not just feeding ourselves well. The UK dog food market was valued at an impressive £1.84 billion in 2023. Home deliveries for dog food are becoming increasingly common.

The growth in these sectors relies on one key factor – temperature controlled packaging, which helps to ensure these products are delivered fresh and safe to eat.

Proper packaging is essential for transporting products that require a controlled temperature environment. Whether you are delivering pharmaceuticals, perishable foods, or other temperature-sensitive items, following the right procedures ensures your products reach their destination in optimal condition.

In this blog we’ll explore the different types of cold chain packaging solutions available as well as provide some tips on how to pack your products.

What is temperature controlled packaging?

Temperature controlled packaging (TCP), also known as thermal or chilled packaging, is designed to maintain a specific temperature range for perishable goods throughout the supply chain. Whether shipping fresh, chilled, or frozen foods temperature controlled packaging helps ensure that items remain in peak condition during transit.

A typical temperature controlled packaging solution consists of an outer cardboard box, an insulating liner, and a coolant such as ice packs or gel packs. These elements work together to maintain the required temperature, protecting the contents from spoilage or degradation.

Which services need chilled packaging?

Chilled packaging is most obviously used for food. Meal kits, fresh meat, and dairy products all require controlled temperatures to stay fresh during delivery. Beyond food, chilled packaging is also crucial for the safe delivery of pharmaceuticals.

Key sectors that benefit from temperature controlled packaging include:

Cold chain airfreight: For transporting perishable goods globally, ensuring they stay at the correct temperature throughout their journey.

Perishable goods delivery: For foods, pharmaceuticals, and medical supplies, where precise temperature control is critical from the warehouse to the customer.

Bulk cold chain stock movement: For moving large quantities of perishable products, such as produce or seafood, through the supply chain.

What are the best packaging products to ship temperature-sensitive goods?

There are three main types of packaging in thermal solutions:

Boxes and liners: These shipping packs include an outer cardboard box and thermal liners. Used with the appropriate coolant, they are ideal for shipping frozen, chilled, or ambient goods. Some examples include:

• RecycoolMe: A sustainable solution made from recyclable paper-based liners.
• CooliMate®: Consists of a double-wall carton and metallised bubble liners, maintaining temperatures of 2-8°C for up to 48 hours.
• Coolants: To maintain temperature during shipping, you need coolants that suit the type of product you’re sending. Options include:
• Ice sheets: Available in multiple sizes, these provide clean and safe cooling.
• Gel packs: Contain highly purified water and maintain a stable shape when frozen, ideal for chilled products.
• Sorbatek: Designed for longer temperature control, particularly suited for shipping seafood.
• Bulk solutions: If you’re shipping large quantities of temperature-sensitive goods, bulk options like insulated pallet boxes, thermal pallet covers, and roll cage covers are available. For example:
• CooliMate® pallet boxes: Easy to assemble and perfect for bulk shipments.
• Breathable air cargo covers: Protect perishable goods in air cargo from temperature fluctuations, moisture, and contaminants.

How to pack chilled foods for transport

Perishable goods will often pass through multiple warehouses and vehicles, so maintaining temperature throughout the journey is crucial. Follow these steps for best results:

Prepare your packaging materials: Pre-assemble the outer boxes and liners before bringing products out of cold storage. Have your coolant, tape, and other materials ready to minimise the time your products spend outside refrigeration.

Limit exposure to warm air: Products should be outside of cold storage for no more than 20–30 minutes before being packed. Extended exposure to room temperature can cause your products to warm the coolant, reducing its effectiveness and cutting transit time.

Use proper coolant placement: Place coolants (ice sheets or gel packs) at the top of the package, as cool air naturally moves downward. This ensures your products remain at the desired temperature throughout transit.

Fill voids for insulation: Any gaps between items should be filled with a suitable void filler to prevent movement and provide additional insulation.

Choose the right coolant for your product:

• For goods to arrive ambient, use ice sheets conditioned to around 20°C.
• For goods to arrive chilled, gel packs or ice sheets are suitable.
• For goods to arrive soft frozen, use duration ice sheets or gel packs.
• For goods to remain frozen, dry ice is necessary.

Keep parcels in cold storage until dispatch: To maximise the effectiveness of your temperature controlled packaging, store your packed parcels in a refrigerated or freezer environment until the delivery vehicle is ready for loading.

Choosing the right chilled packaging solution

In today’s competitive market, effective temperature controlled packaging is essential for businesses shipping perishable goods like meal kits, fresh meat, and raw pet foods. With a variety of packaging options available, from eco-friendly boxes to advanced coolants, companies can find tailored solutions to meet their specific needs. By carefully selecting and packing your products, you can ensure that your temperature-sensitive goods stay fresh and safe throughout their journey to the customer.

For more information on choosing the right solution for your business, contact us today or download our full temperature controlled packaging guide.

The post How to pack food for cold chain delivery appeared first on Macfarlane Packaging.

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

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

Understanding the impact of rising business costs

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

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

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

What is packaging optimisation?

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

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

How packaging optimisation can deliver cost savings

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

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

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

Strategies for packaging optimisation

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

Here are some key strategies to consider:

Using lightweight yet durable materials

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

Redesigning packaging

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

Customising pack sizes to fit product dimensions

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

Implementing automation in packaging processes

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

Reviewing how you order packaging

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

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

What factors should we consider when optimising packaging?

When improving packaging, think about:

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

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

How Macfarlane Packaging can help

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

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

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

Why not contact us today?

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

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

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

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

The importance of bottle packaging

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

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

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

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

Types of bottle packaging available

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

1. Airsac® inflatable bottle packaging

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

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

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

2. Flexi-Hex® bottle packaging

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

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

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

3. Cardboard bottle boxes with dividers

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

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

4. UPS approved spirit packs

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

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

5. Polystyrene bottle packs

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

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

6. Moulded pulp packs

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

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

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

Choosing the right bottle packaging for your business

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

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

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

Support with bottle packaging

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

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

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

While electronics can benefit from the protective properties of standard packaging solutions, they may need specialist protection from electrostatic discharge or ESD.

ESD-safe packaging comes in many forms and is popularly known as anti-static packaging or ESD packaging.

In this article, we’ll provide a comprehensive guide to anti-static packaging, the science behind it and discuss the different types of ESD packaging available.

Understanding anti-static packaging

So, what is anti-static packaging?

Anti-static packaging is packaging that can prevent electrostatic discharge (ESD) from damaging products.

It will sometimes be referred to as conductive packaging, static dissipative packaging, ESD packaging or shielding packaging too. These different types of anti-static packaging all perform similar functions, which we’ll explain later in this article.

Anti-static packaging is often made from materials like polythene or PET films that have additives that prevent static electricity. It can also be made from cardboard with specialist coatings, as well as foam.

The science behind anti-static packaging

Static electricity (or electrostatic discharge) might not seem like a big deal in everyday life. You’ll get a small shock from touching another person or object and think nothing of it.

These shocks are created by electrostatic discharge moving between two objects (or people!). However, this static electricity can create a large amount of heat. This in turn can cause electronic devices to break or become faulty.

Due to this, electrostatic discharge is an extra risk during storage, shipping and transit. Which is where anti-static packaging comes in. It provides protection from the usual rigours of shipping AND can prevent the build-up of static charges, as well as dissipate them.

Why anti-static packaging is important

Electrostatic discharge damage can be costly. It’s estimated by the ESD Association that damages caused by static in the electronics industry can run up to $5 billion. Some major companies suggest that ESD is responsible for 25% electronics part failures too.

In essence, anti-static and ESD-safe packaging help prevent the costly risk that static-sensitive microchips, motherboard and other electronics components might encounter.

So, what types of anti-static packaging are there?

Types of anti-static packaging

Anti-static packaging is often used as a catch all term of packaging that prevents and resits electrostatic discharge. As mentioned earlier in this article, it also known as conductive packaging, shielding packaging and dissipative packaging.

While these terms are sometimes used interchangeably, there are some technical differences:

• Anti-static packaging – this prevents electrostatic charges being created when products may rub against other objects or surfaces.
• Conductive packaging – this type of packaging conducts any potential static charges away from sensitive parts, keeping any flow of electricity under control. It does not accumulate static charges.
• Shielding packaging – this type of ESD-safe packaging provides a barrier that reduces electrostatic discharge.
• Dissipative packaging – this type of packaging slows down the flow of any static charges, rather than directing it like conductive packaging.

Across these types of anti-static packaging, the actual packing material can take many forms. Popular products include anti-static bags, anti-static bubble wrap, anti-static bubble bags and anti-static foam. Usually, these types of ESD packaging are coloured pink, so their distinguishable from their counterparts that aren’t ESD-safe.

Other anti-static shielding bags are metallised to provide protection as well.

In addition to these popular packaging products, you can also get anti-static packaging made from cardboard and corrugated plastic. Examples of these products include:

• Corstat® cardboard – this cardboard creates a Faraday Cage effect, protecting products inside it. It can be used to make anti-static boxes, layer pads, totes and dividers. It can also be used alongside anti-static foam fittings, to provide an all-round ESD-safe packaging solution.

• Corriplast® corrugated plastic – this corrugated plastic is Carbon loaded and provides protection from static charges. It’s very strong and durable, and is resistant to water, grease and other liquids. It’s also suitable for clean room environments. It can be made into boxes, collapsible totes dividers and layer pads, or custom designs.

The benefits of using anti-static, conductive and ESD packaging

Anti-static packaging can provide many benefits. Particularly if you’re an electronics manufacturer or are moving electronic components in industries like automotive, airspace and medical.  

Using ESD-safe packaging can deliver the following benefits:

• Reduced damages – anti-static packaging will ensure your products are protected from static damage, as well as the usual knocks, shocks and drops that could be experienced during handling and shipping.
• Reduced returns & reverse logistics – it can help reduce costly returns, reverse logistics and expensive product replacements by minimising the risk of damages.
• Improved productivity – the benefits provided by anti-static packaging will remove hassle from your packing operation by reducing the handling of returned goods. This will allow you to focus your resources elsewhere.
• Lower packaging costs – efficient, right-size anti-static packaging can help you lower your packing costs. Reducing damage will minimise replacement and reverse logistic costs in your operation too.

Specialist support developing anti-static packaging solutions

Are you looking for ESD-safe packaging?

At Macfarlane Packaging, we have extensive expertise in creating all sorts of packaging solutions. We have anti-static bubble bags, anti-static bubble wrap and anti-static foam rolls available from stock.

Plus, our specialist manufacturing brand can support you with custom packaging designs, including conductive packaging like Corriplast® corrugated plastic, anti-static inserts and conductive Corstat® cardboard packaging.

Get in touch today for more information.

The post A comprehensive guide to anti-static packaging and conductive packaging appeared first on Macfarlane Packaging.

Typically made from linear low-density polyethylene (LLDPE) it is highly stretchable, which means it conforms tightly to the shape of your palletised load, ensuring that it is stable in transit and storage.

Pallet wrap plays a vital role in the transportation and storage of palletised goods but, many companies are keen to reduce their use of the material, for both environmental and cost reasons. 

If you are using pallet wrap, there are lots of opportunities to use less of it, in this blog we’ll show you 5 ways to reduce your stretch wrap use. We will cover:

What is pallet stretch wrap used for?

Stretch wrap is an essential component for palletising goods. The key advantage of pallet wrap is that it prevents your products from shifting, tipping, or falling during transit. It helps to maintain the integrity of the load and reduces the risk of damage or loss.

It also provides a protective barrier around palletised goods, shielding them from dust, dirt, moisture, and other environmental factors that could potentially damage or contaminate products.

Stretch wrap enhances packaging efficiency as it creates a single, cohesive unit or load, making it easier to handle, transport, and store. This process, known as unitisation, improves efficiency and reduces the risk of lost or misplaced items.

How is stretch wrap applied?

Stretch wrap can be applied by either hand or machine, the application type really does depend on what quantity of pallets you are wrapping each day.

Hand application – this is when stretch film is manually applied by hand, which can be done with or without a hand dispenser. All hand-applied stretch films are supplied on standard cores for use with hand-applied applicators or extended cores. 

If you are applying stretch film by hand, it’s important to consider any health and safety risks associated with hand film application, like the weight of the film and the impact of stretching and pulling on the operator.

Machine application – this is when stretch film is applied to a pallet or product using a pallet wrapper, a machine that automatically winds film round a products on a pallet.

A pallet wrapper is recommended if you are wrapping more than 15 pallets per day. 

Machine applied stretch films are extremely strong and versatile, which saves time, resources and packaging materials for high performance applications requiring higher tensile strengths. These films have excellent puncture resistance, good cling, slip and load retention.

What is the environmental impact of pallet wrap?

Pallet wrap is made from linear low-density polyethylene (LLDPE).  As with the production of many plastics, it consumes resources such as fossil fuels and water and has a high CO2 impact in the manufacturing process.

Excessive application of film, or overuse, can be wasteful which also has a negative impact on the environment.  To ensure load stability, operators can apply too much film by either doing too many wraps or, not applying the correct level of stretch or tension to the film. This could be down to inadequate training or inexperience.

Over application of stretch wrap can also happen with machine applied films too.  it’s important to check that the machine settings are correct for the type of stretch wrap you are using.

By using less wrap, fewer resources are consumed, helping to conserve natural resources and reduce the carbon footprint associated with the manufacturing process and material waste.

How can you use less pallet wrap?

We’ve come up with 5 ways to help you use less stretch wrap:

1. Select the best film for your business

When selecting the right pallet wrap for your business, there are two main areas of consideration:

Stretch wrap performance – Selecting a stretch film that provides the right yield strength and performance for the loads being wrapped is crucial. The yield strength denotes the amount of stress a stretch film can withstand without permanently having plastic deformation. Prior to reaching the yield point, a stretch film will elastically deform but will return to its original shape once the stress is removed

The make-up of the products being wrapped – Consider the products being wrapped and look at your weight load (typically per pallet), load profile type, and the transit process the load will experience.

Load profiles can be summarised by three key types:

2. Change the micron of your stretch wrap

If you can reduce the micron of your stretch wrap to a thinner material, you should be able to reduce your overall use of stretch wrap – reducing your impact on the environment as well as material cost.

Advances in technology of stretch wrap manufacturing has given us a new breed of “High performance” stretch film, it  has a much lower material thickness (micron) than traditional heavier film but provides the same, or higher, levels of performance.

High performance pallet wrap provides businesses with an opportunity to wrap more pallets with less film, whilst maintaining high levels of load containment. This can provide businesses with a reduction in material cost and wrapping times, as well as reducing material use and waste.

3. Switch to a recycled content stretch wrap

As explained earlier, stretch wrap does require the use of fossil fuels, which means that the manufacturing process has a high co2 impact.

By switching to a recycled content stretch film, you are not only reducing the use of fossil fuels, but also ensuring that waste material is recycled for reuse, driving a “circle of life” for plastic materials.

Whilst 100% recycled content film is not yet available, both hand and machine applied pallet wrap is available in a minimum of 30% recycled content. 

If you are currently using a virgin film, a switch to recycled content will also reduce your material cost, as a Plastic Packaging Tax of £ 217.85 per tonne is applied to any plastic packaging which does not contain a minimum of 30% recycled content.

4. Use a pre-stretch hand applicator

If you are applying film by hand, consider the type of stretch wrap applicator that you are using as well as safety precautions when using pallet wrap.

A basic hand stretch dispenser simply holds the roll in place whilst the operator walks around the pallet to apply the film.  Film application is reliant on the operator applying a consistent level of tension by pulling the applicator as the film is applied.  Not only can this lead to operator injury, it can also mean that the pallet wrap isn’t stretched to capacity.  This leads to overuse of film, and a higher cost to wrap each pallet.

Consider investing in an applicator with pre-stretch gears, like Wrapplicator, which applies pallet wrap with a consistent 30% stretch. It’s ergonomic design ensures that the stretch wrap can be applied single handedly, without bending or pulling, reducing the risk of operator injury.

Whilst a dispenser like Wrapplicator costs more than a standard dispenser, it will pay for itself quickly by maximising material use and removing incidences of over stretching or snapping film which can slow down the time taken to wrap each pallet – reducing material and labour cost.  It’s ease of use also means that no matter which operator wraps the pallet, you’ll always get the same result.

5. Automate the process

If you are wrapping 15 or more pallets per day, it’s time to invest in a pallet wrapping machine.

An stretch wrap machine optimises film use through advanced technology and precise film application. They calculate the exact amount of film required based on the pallet dimensions, resulting in reduced film use. Many systems have film pre-stretching capabilities, stretching the film prior to application, further reducing the amount of stretch wrap film needed, along with the cost to wrap each pallet.

A stretch wrap machine can typically pay for itself through material savings, within a few months, depending on the amount of pallets being wrapped.

A benefit of introducing a pallet wrap machine is that it can handle a high volume of pallets in a shorter period, reducing the time required for manual labour and enabling workers to focus on other value-added tasks. Once a pallet is placed onto a pallet wrapper turntable, the operator is able to prepare the next pallet ready for wrapping.

How Macfarlane Packaging can help to reduce your stretch wrap use

With a wide range of recycled content stretch wrap, for both hand and machine application, and pallet wrapping machines, Macfarlane Packaging can help you to identify the right film and automation system.

Our specialist load containment team are on hand to conduct a free of charge stretch wrap review, identifying ways for you to improve your pallet wrapping and reduce material use and cost.  Often, a stretch wrap review can reduce film use by 50%.

We’ve a new range of machine stretch films, starting at 10 micron and containing 30% recycled content available with up to 300% stretch, including black pallet wrap.   Our new hand stretch dispenser, the Wrapplicator, will also reduce your cost to hand wrap each pallet.

Contact us today to find out more.

The post 5 ways to reduce the cost and environmental impact of your stretch wrap 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.

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

What is packaging automation?

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

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

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

Types of packaging automation and machinery available

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

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

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

10 decisive benefits of automated packaging

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

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

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

Support with packaging automation in 2024

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

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

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

Here are eight packing operation resolutions to consider for 2024:

Create space to grow your business

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

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

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

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

Identify opportunities to free up cashflow

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

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

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

Boost efficiency with an ergonomic space

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

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

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

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

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

Reduce the amount of packaging material you use

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

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

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

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

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

Optimise your delivery fleet and courier network

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

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

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

Combat labour shortages with packaging automation

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

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

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

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

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

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

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

Meet your sustainability targets for 2024

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

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

Book a packaging review with Macfarlane Packaging

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

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

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

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

Automated pallet wrappers streamline the pallet wrapping process and can revolutionise warehouse operations within any business.

In this article we will explore the signs that indicate how your business could benefit from installing an automated pallet wrapper system, highlighting the advantages it brings in terms of time savings, cost reduction, improved load stability, and enhanced worker safety.

When is an automated pallet wrapper right for your business?

If you are wrapping 15 or more pallets per day, your operation could benefit from installing an automated pallet wrapping system.

Another clear sign t is when the volume of pallets wrapped per day exceeds the capacity of manual labour.  As businesses grow and handle larger quantities of products, manually wrapping each pallet becomes time-consuming and labour-intensive.

By introducing an automated system, you could significantly increase pallet wrapping efficiency as machines can handle a high volume of pallets in a shorter period, reducing the time required for manual labour and enabling workers to focus on other value-added tasks.

Once a pallet is placed onto a pallet wrapper turntable, the operator is able to prepare the next pallet ready for wrapping.

How does an automated pallet wrapper improve load containment?

An automated pallet wrapper can improve your load containment and reduce the incidents of pallets collapsing in transit or storage.

When film in manually applied to a pallet, there is always a risk that load containment can be inconsistent.

Human error, fatigue, and variations in technique can result in inadequate load containment, leading to product damage, instability, and potential safety hazards during transit.

An automated pallet wrapper ensures consistent wrapping tension, film overlap, and coverage, guaranteeing uniform load containment for each pallet.

This consistency minimises the risk of load shifting, topples, and damages, ensuring product protection and reducing the potential for additional operational costs.

What is the impact of a pallet wrapper on improving operation throughout

In fast-paced industries with high throughput requirements, an automated pallet wrapper system can significantly enhance productivity.

An automated pallet wrapper provides rapid and continuous pallet wrapping, eliminating bottlenecks in the packing and shipping process.

By reducing pallet wrapping cycle times, businesses can increase their overall throughput, improve order fulfilment rates, and meet tight delivery schedules.

The consistent and efficient wrapping provided by an automated pallet wrapper also facilitates smoother material handling, speeding up the loading and unloading vehicles.

Can an automated pallet wrapper reduce the amount of stretch film used?

An automated pallet wrapper can help to dramatically increase the throughput of your operation.

The manual application of stretch wrap is reliant on the operator applying tension to the roll, minimising the amount of movement in the material.

If the material is not applied at it’s optimum, you are probably overcompensating by applying more layers of stretch film than necessary.    

An automated pallet wrapper system optimises film consumption through advanced technology and precise film application. They calculate the exact amount of film required based on the pallet dimensions, resulting in reduced film waste and cost savings.

Additionally, automated systems often feature film pre-stretching capabilities, stretching the film prior to application, further reducing film consumption and costs.

What is the impact of an automated pallet wrapper on health and safety

Manual pallet wrapping involves physical labour, repetitive motions, and heavy lifting, which can lead to worker fatigue, strains, and injuries. Automated pallet wrappers reduce the need for operatives to bend, twist and stretch.

By automating the pallet wrapping process, your team can focus on less physically demanding tasks.  This reduces the risk of injuries and promotes a safer work

How long does it take to install a pallet wrapper?

Once the right automated pallet wrapper has been identified for your business, installation is typically quick and easy. If it’s not integrated into a wider automated system, it’s a case of plugging it into a power socket, calibrating the system to apply the right tension for your needs and film used.  With the aid of an automated pallet wrapper expert, you could be up and running in just a couple of hours!

By investing in an automated pallet wrapper, you can save time, reduce costs, improve load stability, and enhance worker safety. Ultimately contributing to a more efficient and competitive operation.

Why not contact us today to find out which automated pallet wrapper will best suit your business?

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