Products that become loose and fall off your pallets during transit and storage can break, leading to increased costs and customer disappointment.

Palletised goods face not only physical damage from knocks and drops but also often need protection against moisture, dirt, dust or even rust, depending on the nature of your products. This blog article will offer 5 tips for palletising bulk deliveries to guarantee that your goods arrive in optimal condition.

We’ll explore the importance of effective palletisation, discuss common challenges and provide guidance on choosing the right pallet. We will also look at the significance of correct load distribution and selecting appropriate packing materials.

Understanding the importance of palletisation

Your goods may encounter various dangers during the shipping process. Ensuring they are properly secured to pallets is crucial for their protection on the way to the end user. The right palletisation can help in several ways:

• Preventing damage – Goods that are not securely palletised may become loose during shipping and storage, potentially leading to damage or causing injuries
• Protecting against moisture and dust – if you are transporting liquid products or your goods are exposed to wet conditions, proper palletisation is essential to protect them when encountering elements, such as moisture and water as well as spills and contamination
• Reducing additional costs – when goods arrive damaged, this often means they will have to be replaced and shipped again, which incurs additional shipping costs and the expenses associated with issuing new items. There are also hidden costs to consider, including labour, administrative tasks, damaged reputation and extra carbon dioxide emissions
• Preventing scratches – Choosing the right materials for palletising your goods ensures they are protected against scratches and chips
• Ensuring happy customers – products that arrive well-presented, damage-free will make a good impression on you customers, Even more so when they don’t have to deal with excess packaging. Good experience may lead to repeat orders and building a strong reputation, resulting in new customers

Common challenges in bulk deliveries

When it comes to bulk deliveries, understanding the nature of your products, including their size and weight, is crucial. This knowledge helps in selecting the appropriate pallet and wrapping materials to ensure the safe delivery of your goods.

Some common challenges in bulk deliveries include:

• Choosing the right type of pallet – This involves selecting a pallet that suits the type, dimensions, and weight of your goods
• Deciding on the most appropriate wrapping material – It’s important to choose a wrapping material that provides adequate protection throughout the supply chain
• Understanding the best methods to secure bulky or oddly shaped goods – Securing bulky or oddly shaped goods can be challenging, but it’s essential to ensure they are held securely
• Preventing accidents and ensuring adequate staff training – Providing a safe and consistent approach to pallet wrapping is crucial, especially when dealing with seasonal staff or when there is a high turnover of staff
• Protecting goods against adverse weather conditions – It’s important to safeguard your goods from adverse weather conditions to prevent damage and contamination.

Our tips for palletising bulk deliveries

Tip 1: Assess your product type

Review the size, weight and fragility of your products and consider the conditions they will be transported in. This will help ensure you select the appropriate pallet type and size and choose the right packing materials for the job.

Tip 2: Choose the right pallet

The ideal pallet type depends on their nature of your goods and your specific shipping needs. There are various pallet types available, each with its own set of advantages and disadvantages, including:

• Wooden pallets – Popular for their availability, affordability and durability, this type of pallet is suitable for a broad range of products and industries
• Plastic pallets – Offering superior hygiene, they are perfect for applications requiring a clean and contamination-free environment. Ideal for shipping pharmaceuticals, medicines, food and beverages
• Presswood pallets – A type of wooden pallet designed for easy stacking, offering space savings while still being able to hold significant weight
• Corrugated cardboard pallets – A lighter pallet alternative capable of holding up to 750kg without the need for heat treatments. This makes them ideal for those wanting to reduce the overall weight of their shipments 
• Metal pallets – Renowned for their strength and durability, they are best suited for heavy-duty applications

For more information about different pallets type and how to choose the right size, read The Ultimate Guide to Pallets and Pallet Sizes.

Tip 3: Optimise load distribution

Ensure your load is stable and its weight is equally distributed across your pallet to optimise product safety. This will help prevent your load from tipping over and collapsing during shipping and storage. Place heavy items at the bottom and lighter on top.

Be cautious not to overload your pallets, as this can strain the packing materials and affect load stability. Always check the weight and load capacity of your pallets and wrapping materials, ensuring you do not exceed recommended limits.

Tip 4: Use appropriate packaging materials

Selecting the appropriate packaging materials is crucial for ensuring the safe delivery of pallets during bulk shipping.

Pallet wraps, such as stretch wrap and shrink wrap are the perfect packing materials to secure your palletised goods. They keep your products in place, offering a safe and tight hold while providing protection against scratches, spills, water and dust exposure. There are different types available, suitable for different product types and applications.

Stretch wrap can be applied manually or with the help of a specialised machine. For instance, the Wrapplicator, an innovative handheld stretch wrap dispenser, simplifies the pallet wrapping process, making it easier and more efficient.

For larger volumes, turntable stretch wrap machines can accelerate your packing operation while ensuring you use only the necessary amount of packing material to protect your goods.

To find out more about different stretch wrap types and uses, read our essential guide to stretch film. Alternatively, if you are interested in shrink films, you fill find more information here: a guide to polythene and shrink film.

You may also want to consider using corner protectors and dunnage to provide additional cushioning and protection for your palletised loads.

Tip 5: Label your pallets for easy identification

Once your pallets are suitably protected, make sure you label your shipments correctly to ensure easy warehouse management and identification of your pallets. It’s a good idea to use clear, quality labels and include information such as product type, quantity and any special handling instructions.

Help with pallet shipping

At Macfarlane Packaging, we offer an extensive selection of protective packaging materials, including various types of pallets, stretch wrap, shrink wrap, corner protectors and more.

We can also provide manual, semi-automatic and fully automatic packaging machines to streamline and optimise your packing process. Contact us today to discuss your specific needs. Our team is here to help you select the most suitable packaging solutions for your unique packaging requirements.

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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.

Choosing the right pallet wrapper can streamline operations, protect your products, and ultimately save you time and money. But how do you decide which pallet wrapper is the best fit for your business?

In this article, we’ll give you an overview of what a pallet wrapper is, the types of wrapper available and tips to help you choose the best pallet wrapper for your needs. We’ll also discuss how pairing the right stretch film with your chosen equipment is critical.

Understanding pallet wrappers

What is a pallet wrapper?

Pallet wrappers are machines that are designed to apply stretch film to a pallet of goods. Most pallet wrappers work by winding film around the pallet, binding items together, providing load stability. This helps secure the goods for safe storage and transport. These efficient devices are also known as pallet wrapping machines or stretch wrappers.

Stretch wrapping machines come in various configurations, from manual and semi-automatic models suitable for smaller operations to fully automated systems capable of handling high-volume production environments. Understanding your specific needs and requirements is key when choosing the best pallet wrapper for your business!  

Types of Pallet Wrappers

There are various types of pallet wrappers available on the market. From manual handheld dispensers, through to more complex machinery. Let’s take a look at them:

Manual pallet wrappers and dispensers

Ideal for smaller businesses with moderate wrapping needs, these dispensers require operators to guide stretch film around a pallet by hand. A great example is our ergonomic Wrapplicator. Its design means operators need to bend less and can just use one hand to apply the film. Manual floor standing pallet wrappers are available too. While manual stretch wrappers are a cost-effective option, they may not be the most effective choice for businesses wrapping more than 15 pallets per day.

Semi-automatic pallet wrappers

These machines automate part of the wrapping process, typically while rotating the pallet on a turntable while applying the film. An operator is responsible for moving the load on and off the turntable or to the wrapping area – hence the machines are classed as semi-automatic. A good example is the popular Lantech QL400 turntable pallet wrapper.

Fully automatic pallet wrappers

Designed for high volume environments, these powerful machines can wrap multiple pallets quickly and efficiently, with minimal operator intervention. Fully automated stretch wrapping machines can often be integrated into packing lines, and form part of a pallet’s movement through the warehouse.

Within these broad categories of pallet wrapping equipment, there are lots of key features and model types to consider too.

• Vertical wrapping, turntable machines – these stretch wrappers apply film vertically, going up and down the pallet. They often feature turntables that rotate the pallet for easy film application or work as a rotating arm stretch wrapper (see below).
• Horizontal wrapping machines – for long profile items, horizontal stretch wrapping machines are also available. Rather than a turntable, these have a conveyor that feeds a product through a tunnel or ring to be wrapped.
• Rotating arm pallet wrappers – good for heavy products or more complex load profiles, these machines feature an arm that rotates around the pallet to apply the film.
• Robot pallet wrappers – rather than a static machine, robot pallet wrappers are portable and move around the contours of a pallet to apply the film. They’re a good choice for heavy or irregular loads, as well as environments where you have multiple wrapping stations, as they can be moved with ease.
• Core break or power pre-stretch machines – most semi and fully automated pallet wrappers will either operate as a core brake machine or a power pre-stretch machine. The main difference between core break and pre-stretch machines is the type of film they use. Pre-stretch machines need to be operated with pre-stretched film. Core break machines work with standard stretch wrap.

Tips for choosing the best pallet wrapper for your business

So, now you know about the different types of stretch wrappers available, but what is the best pallet wrapper for your business?

Every business will have different needs and challenges, combined with the choice out there, it can be hard to decide which type and model of machine is right for you!

1. How many pallets you wrap per day – if you’re wrapping less than 15 pallets each day, a manual stretch wrap dispenser or free-standing manual wrapping machine may be a good choice. If you’re wrapping 15 or more, we recommend looking at semi or fully automatic pallet wrappers.
2. Load profile and stability of load before wrapping – how is your load shaped? Is it very heavy? Can it be moved or does it need to remain static before wrapping? For more complex load profiles or pallets that can’t be moved, robot pallet wrappers, rotating arm machines or even horizontal stretch machines might be right for you.
3. Load stability – once wrapped, does the machine you’re considering provide secure and consistent load stability during shipping and transit?
4. Cost to wrap pallet – the type of machine and film you use can influence how much it costs you to wrap a pallet. With all costs factored in, does the machine you’re looking at provide a lower cost per pallet?
5. Plastic waste and material use  – if you want to wrap more pallets with less film, investing in a good pre-stretch pallet wrapper can be key. They often work well with thin, high-performance films. Performance films can help reduce the weight of the material you use and the waste you create.
6. Packing space and warehouse movement – how much space to do you have for wrapping pallets? Do you pack in one area or more? The footprint available in your site will influence which pallet wrapper you can choose. For example, robotic wrappers may offer more flexibility if you often need to move within your warehouse.
7. Budget – ultimately, you need to factor in which machine will deliver a return on investment for you. The initial costs can be daunting, but they often payback quickly and for many pallet wrappers there are finance options available to spread the cost.

Why the right stretch film is important

In addition to selecting the appropriate pallet wrapper, choosing the right stretch film is equally important. If you choose the wrong film, it can lead to poor load stability and product damage. Not ideal!

Things to consider when choosing the right film include film performance, pre-stretch capability and compatibility with the machinery you’re choosing. It’s worth noting that film thickness can sometimes be misleading. Many high-performance films are quite thin but provide the performance of a traditionally thicker film!

By investing in high-quality stretch film that complements your pallet wrapper, you can enhance load security, minimise product damage, and improve overall operational efficiency.

Conclusion

In conclusion, selecting the best pallet wrapper for your business involves careful consideration of your specific requirements, budget constraints, and long-term goals.

Ultimately, whether you choose manual, semi-automated or fully automated machinery, selecting the right pallet wrapper and stretch film is essential for maintaining the integrity of your shipments. Assess your options carefully and invest in a solution that meets your needs both now and in the future.

If you need help evaluating your wrapping needs or want a recommendation of the best pallet wrapping machine for your business, check out our stretch wrap review service. Alternatively, contact us to speak to one of our experts.

The post What is the best pallet wrapper for your business? appeared first on Macfarlane Packaging.

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

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

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

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

Understanding Bubble on Demand

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

What is on demand bubble wrap?

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

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

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

How on-demand bubble wrap works

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

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

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

Common uses for on demand bubble wrap

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

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

Unpacking the Benefits of Bubble on Demand

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

Cost effectiveness of bubble on demand

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

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

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

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

Environmental impact of using bubble on demand

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

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

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

How bubble on demand can streamline your packing process

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

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

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

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

Comparing Bubble on Demand and Buying Bubble Wrap

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

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

Conclusion

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

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

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

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

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.

If you use stretch film to wrap your pallets and are looking for cost savings, please read on… there may be opportunities to switch materials and bring down the cost of your packing operation.

Performance stretch film, a specialised type of pallet wrap, offers significant cost-saving advantages.

In this article, we’ll uncover how performance stretch film can reduce operating costs by minimising material waste, improving load stability, optimising inventory management, enhancing operational efficiency, and reducing the risk of product damage.

We will cover:

How does performance stretch wrap reduce material waste?

Traditional stretch films require multiple layers of film to be applied to the pallet to achieve a good level of load containment. 

Performance stretch film has superior elongation and cling properties, enabling it to be stretched further with fewer revolutions around the pallet. This reduces the amount of film required to wrap each pallet, reducing material use and, in turn, packaging waste.

The reduction in film required to wrap each pallet not only saves money on packaging material costs and operating expenses but also reduces the tonnage of film entering waste streams. This will reduce your impact on the environment.

The impact of performance stretch wrap on load containment

Traditional stretch films require multiple layers of film to be applied to the pallet to achieve a good level of load containment. 

Performance stretch film has superior elongation and cling properties, enabling it to be stretched further with fewer revolutions around the pallet. This reduces the amount of film required to wrap each pallet, reducing material use and, in turn, packaging waste.

The reduction in film required to wrap each pallet not only saves money on packaging material costs and operating expenses but also reduces the tonnage of film entering waste streams. This will reduce your impact on the environment.

Download our free stretch and pallet wrap guide today! We highlight the different types of film, and help you find the best application method and material for your business!

The knock-on effect of performance stretch wrap on inventory management

Performance stretch wrap can have a positive impact on inventory management.

Firstly, as you are using less film to wrap each pallet, you will purchase and hold less material on site – freeing up warehouse space and reducing cost.

Secondly, the use of performance stretch film can contribute to optimised inventory management of stock. Its excellent load containment properties can provide better stackability, enabling you to achieve higher stacking heights without compromising stability. This maximises warehouse space utilisation, reducing the need for additional storage facilities or costly expansions.

The improved load containment also decreases the likelihood of stockouts caused by damaged inventory.

By optimising inventory management, businesses can reduce carrying costs, improve order fulfilment rates, and enhance overall operational efficiency.

The effect of performance stretch wrap on operational efficiency

Performance stretch film enables faster and more efficient pallet wrapping processes. As less material is used, with fewer rotations around the pallet, it takes much less time to wrap pallets.  Increasing productivity and operation throughput.

Another consideration is the high puncture resistance of performance stretch film, this reduces the occurrence of film breakage or tearing during wrapping, minimising interruptions, and the need for rewrapping.

These efficiency gains lead to continuous improvement in many areas of your business, most of which are identifiability inefficient. These include time savings, streamlined operations, and ultimately, cost reductions.

Is performance stretch wrap right for my business?

If you are shipping out pallets and have an eye for cost reduction then, yes, performance stretch wrap is right for our business.  

We recommend that you engage a stretch wrap expert to take a look at the way you are currently wrapping your pallets and conduct a load containment stretch review. These typically take less than an hour and often, can reduce your stretch wrap use by up to 50%!

Performance stretch film offers a range of cost-saving benefits. By minimising material waste, improving load stability, optimising inventory management, enhancing operational efficiency, and reducing the risk of product damage, performance stretch film can significantly impact operating costs.

Introducing performance stretch film to your packing operation only reduces film consumption and disposal expenses but also improves product integrity, increases productivity, and enhances customer satisfaction.

Embracing performance stretch film as a cost-saving measure is a strategic investment that can enhance the overall profitability and competitiveness of businesses in today’s demanding market.

Macfarlane packaging offers free-of-charge load containment stretch reviews. In under 1 hour, we analyse your film performance, load stability & wrapping costs. As well as recommending the optimal pallet wrapping equipment for your operation.

If you would like to find out more, please visit click here!

The post How performance stretch film can reduce cost in your packing operation appeared first on Macfarlane Packaging.

If you are operational throughout Europe, there are many moving parts at play that can absorb high levels of administration time and drive-up cost.

In this article we will explore the time and cost implications that can be experienced when managing multiple packaging suppliers throughout continental Europe. 

We will consider the freedom of product movement across the continent, how packaging legislation could affect the way you to trade in some countries, common barriers to smooth transactions, as well as opportunities for cost reduction.  

What is the European Union and how does it control the movement of materials

According to the United Nations, 44 countries make-up Europe, of which 27 are member states of the European Union.

Formed to promote peace and economic stability after World War II, the European Union is built on a foundation of binding treaties which, over the years, have harmonized laws and adopted common policies:

• a customs union;
• a single market in which capital, goods, services, and people move freely;
• a common trade policy;
• a common agricultural policy;
  • aspects of social and environmental policy;
  • a common currency (the Euro).

To be eligible for EU membership, countries must first meet a set of established criteria, including having a functioning democracy and market economy. Once a country becomes an official candidate, negotiations are a long and complex process in which the applicant must adopt and implement a massive body of EU laws and regulations. 

There are currently 8 candidate countries working through negotiations and a further 2 potential candidate countries.

Only twenty of the twenty-eight EU member states use the Euro as a form of currency, and 22 members participate in the Schengen area of free movement (where internal border controls have been eliminated).

So, whilst much of Europe is governed with a commonality of regulations, there are still a high number of countries which operate outside of these, introducing a level of complexity required to navigate individual country customs, taxation and paperwork.

The impact of packaging taxation in Europe

On January 1^st, 2021, the EU implemented a plastic tax levy to each member state, requiring them to pay €800 per tonne of non-recyclable plastic used.  Individual country contributions are calculated based on their own national waste database figures.

How each state country recoups these costs is at their own discretion.  Many of the countries have, or are in the process of, bringing in their own packaging taxes and regulations for packaging disposal, to claw back the levy costs.

Unfortunately, there is no unified recycling scheme across the European Single Market either, so each country operates differently.

Some countries require businesses to hold a valid packaging license to cover the cost of end-of-life recycling.  This licence is required even if your business does not operate within that country.  For example, an ecommerce company operating outside of France, requires a packaging licence to deliver goods into the country. 

In January 2024, the new EU Corporate Sustainability reporting comes into force, and will apply to all large companies operating in the EU, including those with non-EU parent companies. Mandatory reporting on packaging use will be required, with businesses expected to itemise the total weight and material make-up of packaging used. It’s hoped that this will deliver transparency of a business’s environmental impact, social affairs and governance matters.

Complexities of packaging supplier management in Europe

Packaging supplier management impacts many touchpoints throughout a business operation. From the initial research to find the right product capabilities, ensuring corporate governance and credit checks, through to contract negotiation, it takes up valuable time to find new suppliers and source products.

There is also an impact on day-to-day transaction management – order placement, goods-in unloading and put away, paperwork handling, invoice matching and payment can take up significant time when replicated across multiple suppliers. Each of these have an impact throughout your operation and become much more complex when you are managing suppliers across borders. 

Throw into the mix the potential for language barriers – there are over 200 spoken in Europe. This can make it challenging to identify supplier specialisms, product quality and supply chain robustness.

It can become administratively overwhelming to track deliveries from multiple suppliers, in a variety of languages. Absorbing valuable time to track logistics, implement cross border quality checks and collate all the reporting.

The impact of multi-currency trading

Only 20 of the 44 European countries trade using the Euro, which means there is a high chance that you will need to trade in multiple currencies. 

Multi-currency bank accounts are available but are chargeable. Currency fluctuations should also be considered – you may get a favourable rate of exchange on the first order placement but, it may not be so competitive when you place the follow-up order. 

As well as the direct financial costs, there will also be an impact on how you handle those transactions through your business systems.  Does your software allow you to transact in multiple currencies? Are you able to manage SKUs, purchase orders and invoicing in a variety of currencies? 

Business software may need to facilitate multi-lingual trading too – placing purchase orders or receiving order confirmations and invoices for example.

Simplifying your European packaging supply chain

If the above scenarios are familiar and you’re looking for ways to simplify your European packaging supply chain then supplier consolidation with a partner who operates across Europe could help to streamline your business.

Macfarlane Packaging supports customers with European operations through our distribution service and easy e-trading portal.  We source your packaging and provide a single point of contact for all of your packaging SKUs.  We transact in the language of your choice and invoice in a single currency.

Our online easy ordering portal integrates with your systems and brings together your sites, your orders and tracking. All supported with “touch of a button” reporting.

With ISO9001, 140001, Sedex and EcoVadis membership, we deliver peace of mind, as well as packaging, to your packing operation.

The post Managing European packaging supply chain continuity appeared first on Macfarlane Packaging.

Rents have been steadily increasing across the UK over the past few years, with an average annual rental growth rate of 4.2% estimated between 2022 and 2026.

Optimising your warehouse space is key to helping keep the costs down and ensuring your packing operation runs smoothly. 

In this blog article, we will look at packaging automation and how it can help you reduce costs and maximise your warehouse space.

What is packaging automation?

Packaging automation is the process of introducing automated tools and packaging machinery to increase the speed of packing without manual intervention. It ensures consistency, reduces material waste and helps generate cost savings in the long run.

Types of packaging automation

There are different types of packaging automation, depending on your needs. You can automate pretty much anything from packing and void filling cardboard boxes to taping and wrapping your pallets ready for shipments. Some of the most common solutions include:

• Box automation – case and box erecting solutions, as well as automated boxing machines, designed to open, fold and seal your boxes, depending on the equipment used. Automated box-sizing machines measure the size of products and adjust the box size to offer the best fit for the content.
• Protective automation – examples include semi and fully automated void fill systems, as well as air cushioning and air pillow machines. Depending on the model, air cushions can be automatically inflated, cut to size and placed inside the boxes.
  
• Paper automation – this can involve anything from void filling, through to wrapping and cushioning. Paper void fill dispensers can be programmed to release specific lengths of material for each of your pack options.
• Automated taping – semi and fully automated tape dispensers and machines that can automatically release and cut your tape to specified lengths. This helps ensure you are getting the right amount each time.
• Automated bagging – fully and semi-automated bagging solutions that can automatically prepare, fill, cut to size and seal your bags to ensure optimal fit.
• Stretch Automation – these include fully and semi-automated pallet wrappers, horizontal and vertical stretch wrapping machines, as well as rotating arm stretch wrap machinery.
  

We also distinguish between semi-automated and fully automated packaging processes.

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

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

The benefits of packaging automation

Packaging automation has many benefits to offer. It helps lower your operational costs, improve pack line productivity and save valuable storage space. It also ensures consistency in packing, warranting all products are packed to the highest, uniform standard.

Smaller, compact parcels, that result from using automation, will take up less space on your delivery vehicles. This means you will need to make fewer trips to deliver your products, reducing your fuel costs and keeping your cardboard emissions down. 

The initial investment involved in purchasing and setting up the required packaging machinery may be off-putting, however, automation will help you generate significant cost savings in the long run.

Ultimately, you will be spending less on your materials, labour and transportation. Optimised packaging will also help reduce the risk of product damage in transport, minimining costs involved in processing returns.

Packaging automation and storage space

Packaging automation can play a big role in optimising your warehouse space. It helps reduce the amount of packaging products you need to store in your warehouse, which creates more room for other operations and saves costs. 

Automated packaging solutions ensure your parcels are neatly packaged with just the required amount of material. This helps prevent overpacking and material waste, freeing up your storage space.

Is packaging automation right for me?

If you are struggling with warehouse space or are simply looking for ways to improve the efficiency of your packing operation, packaging automation may be the right solution for you.

Signs your business is ready for packaging automation include:

• Your packaging is increasingly taking up room in your warehouse
• You continually need to hire new staff for your production and/or pack line
• Your packs per hour aren’t increasing in line with demand
• Your business is creating increasing levels of packaging waste
• You experience an uplift in customer complaints about damaged goods
• Your packing team’s morale may be lower due to increased workload

Support with packaging automation

If you are struggling with your warehouse space, Macfarlane Packaging can help you determine which automated packaging systems are best for you, and which points in your supply chain will benefit most from using automation.

We can also recommend a range of semi-automated packaging solutions if you are looking at trying it out on a smaller scale.

We have solutions to fit different needs and budgets.

Why not contact us today to discuss your specific requirements?

The post How packaging automation can release warehouse space appeared first on Macfarlane Packaging.