Category: Case Study

The problem:

Our customer wanted to switch from polypropylene tape to water-activated tape to enhance packaging efficiency and improve their sustainability proposition.

Our approach:

Installing water-activated tape and dispensing machines is structured, collaborative, and results-driven. We begin by assessing the current packing operation to understand workflows, carton types, and throughput.

Working closely with the team, we identify specific requirements and tailor the solution accordingly. Once aligned, we oversee the installation of the machines, provide hands-on training to staff, and ensure seamless integration with existing processes.

Post-installation, we monitor performance and offer continued support to optimise efficiency and long-term value.

The results:

• Cost neutral solution

• Improved pack speed

• Scalable solution – ready for growth
• Delivered a more sustainable, recyclable packaging solution

The problem:

Loss prevention was compromised due to challenges with the automated box closing machine.

Our approach:

Our analysis revealed that the current adhesive technology was unsuitable for that specific application.  We consequently recommended another more suitable product. Validated through extensive and robust testing. 

The result:

• Reduced closure failures from 8% to 1%.
• Regular glue tank maintenance halved.
• Adhesive reduced by 28%.
• Cost neutral solution.

The problem:

Our client wraps and transports thousands of pallets daily from multiple distribution centres to their high street stores.  They tasked us to reduce pallet wrap costs whilst improving load stability.

Our approach:

Working with the onsite teams, our initial analysis quantified the current cost to wrap a pallet and the load stability values.  Following extensive trialing of different Machine film we identified the optimum product.  An extended validation process ensured these gains were maintained within the daily operational environment and this was supported by site operative and delivery driver feedback.

The result:

• Reduced cost per pallet by 13%.
• 8% more pallets wrapped per hour.
• Implemented a 30% recycled content film.
• Improved load stability, resulting in safer pallets and loads.

The problem:

The retailer was facing a significant issue: the excessive and improper use of void fill and cushioning materials was driving up costs and contributing to a higher rate of product damage.

Our approach:

After thoroughly reviewing SKU’s and order profiles, we identified the optimal box sizes and void fill solutions to minimise waste. To embed this approach, we launched a comprehensive training platform for staff.  Supported by on-going refresher sessions to ensure consistent high-performance packing methods.

The result:

• 20% reduction in void fill.
• Increase in overall operational efficiency.
• Significant reduction in damages.

The problem:

The household brand wanted to reduce packaging costs without lowering the customer experience or having any impact on their operation.

Our approach:

We looked closely at packing speeds, the best pack sizes, and how it all impacts the customer experience. By teaming up with colleagues and carriers, we fine-tuned our test and learning methods, trying out different options to see what worked best for performance speed and cost.

The result:

• Pack speed increased by 27%.
• Moving from box to envelope, we removed 50% packaging material.
• Overall annual saving of £280k.

The problem:

To automate the pack process for pet medication products and reduce the cost per pack, increase productivity and future proof the system for anticipated growth.

Our approach:

By conducting a detailed analysis of the cost per pack, productivity metrics, and maintenance expenditures we were able to quantify the ROI for each option.  This comprehensive data ensured all the stakeholders had access to the critical information required for making informed decisions.

The result:

• Reduced cost per pack by 40%.
• Increased productivity by 37%.
• Packaging material reduced by 50%.

The problem:

Our client was two years into a project to ship the UK’s first ‘Ready to ride bike’, the trouble was that they needed a 100% corrugated pack – no plastic – at a size their carrier could handle.

Our approach:

An on-site workshop allowed us to fully understand the product and its journey. After working with manufacturing partners and expert engineers, endless revisions in our design facility and shipping multiple prototypes for performance validation – we cracked it!

The results:

• Successfully shipped the inaugural ‘Ride ready bike’.
• 100% fully recyclable pack.
• No damages reported in 12 months.

The problem:

Our customer’s internal team had already made significant progress and had explored the most available opportunities to reduce waste to landfill.  By taking a collaborative and supportive partnership approach, we were able to help them dig deeper and identify new, previously overlooked opportunities for further improvement.

Our approach:

Through close collaboration with on-site teams, we conducted a detailed assessment of current packaging processes and materials.  This analysis revealed an opportunity to implement linerless labels.  An efficient sustainable alternative with no backing paper.

The result:

• Zero waste to landfill
• Reduced carbon footprint
• Eliminated the plastic tax payment
• 40% more labels per roll
• Reduced in-house maintenance