Case Study: Smarter Packaging Solution Saves Over £39,000.

The Challenge:

A high-volume customer was regularly shipping up to 2,000 pallets of boxed printed materials each month.

To protect the boxes during transit, they used a combination of four edge protectors to form a top frame and four vertical corner uprights.

However, their current method had several issues:

Time-consuming process:

Each pallet took around 5 minutes to pack and typically needed two packers.

Inefficient materials: They experimented with self-adhesive tape, but it caused damage to the printed boxes and had to be scrapped.

High labour cost: The manual method added up to over 330 hours a month, costing around £4,125.

Our Approach

We explored a range of alternatives and ultimately introduced our innovative locking-tab edge protector.

This solution came in a single pre-creased length, allowing it to fold neatly around the pallet without the need for taping or separate components.

The clever locking tabs securely held the shape in place, streamlining the entire packing process.

The Results

The outcome was clear:

   ✔️ After a short familiarisation period, the new system delivered immediate improvements:

   ✔️ Packing time reduced by 40%, from 5 minutes down to under 3 minutes per pallet
Labour requirement dropped, freeing up staff for other tasks.

   ✔️Monthly savings of over £3,290, equating to an annual saving of £39,500
45% cost reduction in packaging labour.

Conclusion

This simple but smart change to a more efficient packaging solution not only saved time and money, but also improved workflow and reduced packaging complexity.

It’s a great example of how thoughtful design can make a big impact on the bottom line.