Examples of packaging process optimisation at our clients’ sites [case studies]
The enquiries we receive from customers fall into several categories, including those in which:
- the discussion centres on price and technical specifications,
- whose aim is to discuss changes to the packaging system and optimisation.
Sometimes, too, we start with price and specifications, and end up providing comprehensive or targeted support in changing packaging methods. That is why we say we are ‘more than just a packaging manufacturer’ – because we don’t just send a dry file with a quote (unless that is what the customer wants), but we share our knowledge gained from working with leaders in various industries (automotive, furniture, glass, logistics, etc.) and suggest how and what can be modified in the packaging process to:
- reduce packaging costs;
- streamline the work of warehouse staff and packers;
- use fewer materials and generate less waste;
- adopt more sustainable solutions (e.g. those that are homogeneous in terms of recycling).
Below are a few selected optimisation case studies that we have helped our clients implement and which have brought about tangible improvements in terms of process time and cost.
CASE #1
INDUSTRY: Furniture | COMPANY SIZE: 500+ employees | REACH: European
- PROBLEM:
A client in the furniture industry was struggling with a multi-layered packaging system, which meant a longer process and more different materials to order and store. As is often the case in many industries, sofas were wrapped in thin dust-proof film, followed by cardboard corner protectors, then corrugated cardboard, and finally the product was wrapped in thick LDPE film.
- SOLUTION IMPLEMENTED:
We suggested to the client that they reduce the number of layers whilst increasing protection – the cardboard and thin dust-proof film were replaced with a laminate of PE foam and bubble wrap.
- EFFECT:
Fewer layers of material, and therefore shorter packing times. Better protection (as it is made from waterproof, dust-free material, unlike cardboard) and less storage space required for packaging materials.
CASE #2
INDUSTRY: Sanitary ware | COMPANY SIZE: 700+ employees | REACH: European
- PROBLEM:
The client’s staff were wrapping a wide range of similarly shaped products, including toilet seats. Wrapping them in bubble wrap meant that it was up to the staff to decide how much material to use in practice – one person would wrap a product once, another twice – so consumption was often higher than necessary, making stock planning more difficult. Furthermore, this method of packaging required the additional use of adhesive tape to secure the ends of the material.
- SOLUTION IMPLEMENTED:
We suggested that the client use pre-made bubble wrap bags instead of rolls. This meant that each flap was packed in the same amount of material (one bag), and there was no need to seal the product with tape.
CASE #3
INDUSTRY: Health & Beauty | COMPANY SIZE: 30+ employees | COVERAGE: nationwide
- PROBLEM:
The customer would place small bottles into polystyrene moulds, which were then put into cardboard boxes. Unfortunately, such small moulds broke and crumbled easily, and it was difficult to remove them from the box.
- SOLUTION IMPLEMENTED:
Foam fittings have proved to be a viable alternative to polystyrene fittings. As they are flexible, they are easier to remove from the box, do not crumble, and are less of a challenge to store.
CASE #4
INDUSTRY: Home & Decor – E-commerce | COMPANY SIZE: 50+ employees | COVERAGE: nationwide
- PROBLEM:
One of our clients, who ships products of very different sizes, often had to fill empty spaces in parcels. At that stage of development, they were unable to automatically tailor cardboard boxes to each order or keep dozens of boxes of different sizes in stock. They filled the empty space with bubble wrap (for practical and economic reasons – they sold low-margin products), but the need to secure the parcels resulted in very high consumption of the wrap.
- SOLUTION IMPLEMENTED:
We suggested a simple change to the client – switching from standard bubble wrap with small bubbles to FILL&WRAP, which features large bubbles (three times the size). This meant that the same length of wrap could fill more space in the parcels more effectively.
- EFFECT:
Film consumption has fallen, and the packaging process has become more efficient – staff no longer have to unroll ‘miles’ of film per parcel.
We can help you and optimize the packaging process in your company
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