Sustainable Packaging Solutions for Made-to-Order Businesses

In industries that predominantly operate on a made-to-order basis, such as doors, panels or shutters, rising customer demand for environmental responsibility is pushing manufacturers to rethink their processes. Whether it’s reducing carbon emissions by changing material suppliers or upgrading packaging solutions, companies are increasingly seeking ways to align with sustainability while maintaining product protection, visual appeal and bottom-line profits.

Made-to-Order Packaging

Manufacturers in the doors, panels, and shutters industry cover a wide range of clients, from individual homeowners with smaller orders to large-scale construction projects. Regardless of the order size, packaging plays an important role in ensuring products arrive in perfect condition. Given the intricate finishes and personal details that often define these products, standard packaging solutions frequently fall short.

Traditional packaging practices, such as relying on oversized boxes and plastic void fillers, lead to unnecessary waste, higher costs and a greater risk of product damage. This is where Right Size packaging steps in to provide a more tailored, sustainable, and efficient solution.

The Benefits of Right Size Packaging

Right Size packaging is designed specifically for each product, minimising empty space in the box and reducing the need for filler materials. This approach not only lowers packaging costs but also significantly reduces the risk of damage during transportation, ensuring that products reach customers intact and undamaged.

Additionally, Right Size packaging streamlines production by enabling on-demand creation. This helps free up valuable warehouse space and increases the overall packaging process, contributing to a more efficient supply chain.

Case Study: Evergreen Shutters

We recently spoke with Evergreen Shutters, a leading manufacturer who faced packaging challenges due to the variety of custom-made shutters they produced. Standard packaging solutions led to excessive use of filler materials and frequent product damage. Their solution? Implementing Right Size packaging in partnership with Ribble Packaging. You can read the full case study to learn how Evergreen Shutters improved their packaging processes and saw long-term benefits from adopting Right Size packaging.

While transitioning to Right Size packaging is a commitment, the long-term benefits such as cost savings, reduced waste, and improved product protection are undeniable. Adopting made-to-order packaging is not just a practical step but a strategic decision that positions manufacturers for long-term success in a competitive and sustainability-focused market.

Take the Next Step with Ribble Packaging

If you’re ready to discover how custom packaging can transform your business, reach out to us at Ribble Packaging on 0161 284 9000 or through our website. Our team of experts can advise on the best options to meet your business needs, helping you enhance sustainability and reduce costs.

Traditional Packaging Fails The Lighting Industry

The lighting industry is a dynamic market characterised by innovation and growing consumer demand for both residential and commercial use. As lighting products change over time becoming more energy efficient, technologically advanced and complex, so too does the need for effective packaging. Packaging is not only the protective layer, but an important step in the delivery of these products, ensuring they reach customers intact and fully functional.

Today’s Complexity of Lighting Products

Over the past decade, the lighting market has seen considerable change. The widespread adoption of LED technology, which offers longer life spans and greater energy efficiency, has transformed product design and customer expectations. Alongside this, the increase in smart lighting systems adds a layer of complexity to the products themselves. These innovations require packaging that can not only protect delicate components, but also match the high-tech image these products now hold.

Avoid Traditional Packaging Methods

Traditionally, lighting products have been packaged in standardised boxes, often selected based on availability rather than fit. This approach frequently results in a mismatch between the product and its packaging, necessitating the use of plastic fillers, bubble wrap, and other void fillers to cushion the product during transit. While these materials provide some level of protection, they add to the overall cost and contribute significantly to environmental waste, a growing concern for both customers and regulators.

Choosing Right Size Packaging Solution

As lighting products become more advanced, companies like Ribble Packaging are at the forefront of this shift with our ‘Right Size’ solutions.

Ribble Packaging’s Right Size offers a transformative solution to these challenges by allowing lighting manufacturers to produce custom fit boxes on demand. The process is designed to be user-friendly, efficient, and highly adaptable to the specific needs of each product.

The process begins with the selection of the appropriate box size and style from an archive, accessed via an integrated touch screen. This interface allows operators to quickly and easily choose the exact dimensions and specifications required for each product. Once the selection is made, the system automatically sets up the production of the box.

Panotec Technology

Panotec’s packaging machine then cuts and creases the box to match the precise measurements of the product. This ensures a perfect fit, eliminating the need for additional void fillers and reducing the risk of damage during shipping. Once the box is produced, it can be assembled immediately, ready to package the product securely.

This on-demand production model not only improves the fit and protection of the packaging but also reduces the amount of storage space required for packaging materials. By creating boxes as they are needed, manufacturers can significantly reduce their packaging inventory, freeing up warehouse space for other uses.

For lighting manufacturers looking to improve their packaging process, reduce costs, and their environmental footprint, Ribble Packaging’s Right Size solutions represent a significant step forward. By rethinking how packaging is approached, manufacturers can ensure they are not only meeting the demands of today but also positioning themselves for the future.

If you’re interested in the possibilities of Panotec, our team can be contacted on 0161 284 9000 or alternatively through our website.

An Update on the EPR Regulations on Packaging and what that means for you

Extended Producer Responsibility (EPR) has been introduced to reshape packaging waste management in the UK and Europe. If you want to understand more about how this will impact your packaging, then stick around.

As the environmental impact of packaging continues to draw public and governmental scrutiny, EPR regulations are increasingly mandating that producers take full responsibility for the lifecycle of their packaging. Effective from October 2025, these regulations are going to change how businesses approach packaging design, production and disposal.

What is EPR?

Extended Producer Responsibility (EPR) is a framework that assigns producers significant financial and physical responsibility for the treatment and disposal of post-consumer products. The primary goal of EPR is to incentivise producers to incorporate environmental considerations into the design of their products and packaging, ultimately reducing waste and promoting recycling.

Key Changes in the EPR Regulations

The upcoming EPR regulations in the UK bring several key changes that businesses need to be aware of:

  1. Producers will be required to cover the full net costs of managing packaging waste, including collection, sorting, recycling, and disposal. This includes payments to local authorities for handling household packaging waste​
  2. Companies must report on the packaging they place on the market. This data must be submitted bi-annually, covering the volume and type of packaging materials used, to ensure accurate calculation of waste management fees​
  3. Producers will need to obtain Packaging Waste Recycling Notes (PRNs) or Packaging Waste Export Recycling Notes (PERNs) as evidence that their packaging waste has been recycled. This system aims to ensure transparency and accountability in the recycling process​

    More information can be found here (GOV.UK)​​.

Impacts on Packaging Design and Materials

The new EPR regulations are set to also impact how businesses design and choose materials for their packaging. To comply with EPR standards, companies are encouraged to use sustainable and recyclable materials. This shift is driving innovation in packaging design, with many businesses exploring alternatives. In reviewing packaging, many companies have already seen a reduction in excess packaging through Right Size packaging.

While there may be initial costs associated with transitioning to sustainable packaging, the long-term benefits include reduced waste management expenses and improved resource efficiency. Additionally, compliance with EPR regulations can help companies avoid potential fines and penalties. Other benefits have shown companies that adopt sustainable packaging practices can improve their green credentials and appeal to environmentally conscious consumers, demonstrating a commitment to sustainability can differentiate a brand in a competitive market.

Practical Steps for EPR Compliance

Businesses across the UK should start by assessing their current packaging materials and practices to identify areas for improvement. Once identified, work closely with packaging suppliers to develop sustainable solutions that meet EPR standards. Suppliers like Ribble Packaging can offer expertise in optimising packaging and material selection.

Consult the Experts at Ribble Packaging

The EPR regulations mark a significant shift in how packaging waste is managed in the UK. While these regulations pose challenges for businesses in terms of increased costs and compliance requirements, they also offer opportunities for innovation and sustainability. By staying informed and proactively adapting to these changes, companies can not only comply with the regulations but also enhance their environmental impact.

At Ribble Packaging we specialise in providing EPR compliant packaging solutions tailored to your business needs through Right Size Packaging. Contact us today and see how we can help you understand the complexities of EPR regulations.

For more detailed information on the EPR regulations and their implementation, you can visit the official UK government pages (GOV.UK)​​.

Your Questions Answered: Insights on Packaging Automation

Packaging automation is revolutionising how businesses operate, offering unparalleled efficiency, cost savings, and sustainability. We are often asked about packaging automation, how does it work? Does it live up to the hype? What options are there? Etc. So we thought we would compile a list of the most common questions asked and answer them here. Read on to understand how this technology can transform your operations:

 

 1. In what ways can packaging be automated?

Automation can be implemented across various stages of the packaging process, it can be anything from box forming to labelling or palletising. Offering a wide range of solutions to optimise efficiency.

 

2. What are the key benefits?

Packaging automation offers a multitude of benefits that can significantly enhance a company’s operations and bottom line. It boosts productivity by streamlining processes and accelerating production times.

It leads to a notable reduction in costs, as automation minimises expenses associated with manual labour, material waste, and resource inefficiencies. What’s more, automation systems offer unparalleled flexibility, allowing companies to seamlessly upscale their operations to meet growing demands without major disruptions or additional resource investments.

In addition, by automating repetitive tasks, businesses can save on labour costs while reallocating employees to more strategic roles.

Automation technology also addresses common packaging process issues in real time, ensuring consistent, high-quality output with every box produced. Ultimately, packaging automation guarantees precision and accuracy, delivering perfectly packaged products consistently.

 

3. Are there opportunities to scale up the solution?

The beauty of Panotec Automation is that businesses can start with a single module of automation, maybe addressing a specific packaging challenge, and as the company grows and operations expand it has the ability to scale up to a fully automated solution.

 

4. How does automation enhance sustainability?

Firstly, it promotes efficient resource usage by reducing energy consumption and minimising waste, it does this by optimising packaging dimensions, producing the perfect sized box every time, conserving valuable materials and avoiding the need for excess void fillers and plastic packaging.

Secondly, automation also contributes to improved product quality by ensuring consistent packaging, resulting in fewer damaged products and returns, which ultimately saves both money and resources.

Furthermore, when partnered with suppliers like Ribble, who exclusively utilise 100% recyclable, environmentally sustainable packaging materials, it further reinforces sustainability initiatives by ensuring that the entire packaging lifecycle aligns with eco-friendly practices.

 

5. How has the reception been so far?

The reception has been overwhelmingly positive. Ribble has received fantastic feedback from several of our clients who have experienced remarkable results. For instance, one client managed to slash their packaging spending by an impressive 50% within the first 12 months, leading to savings of £200,000. Another client anticipates producing half a million boxes on-site annually, with the automation equipment projected to recoup its costs in just two years.

 

6. How will independent retailers benefit?

Independent retailers stand to gain numerous benefits, automation can significantly enhance operational efficiency, allowing retailers to streamline their packaging processes and fulfil orders more quickly. This increased efficiency translates to faster turnaround times, enabling retailers to meet customer demands promptly and maintain high levels of customer satisfaction.

By automating repetitive and labour-intensive processes, retailers can allocate their workforce to more value-added activities, ultimately maximising productivity and improving overall operational effectiveness.

Automation also has the ability to minimise losses associated with product damage and mishandling. We’ve all experienced the frustration of receiving damaged products in the post, which can significantly impact customer satisfaction. By leveraging automation, retailers can enhance the consistency and protective measures of their packaging, reducing the likelihood of damage during transit. This not only preserves the integrity of products but also fosters positive customer experiences.

 

Panotec Automation provides customised solutions to suit all your packaging needs. Whether you require a variety of different size boxes for your products, or you are looking to remove void fillers from your packaging process, Panotec has a solution suitable for all sizes of business. Speak to the team about implementing Panotec Automation into your business. Contact us or call 0161 284 9000.

Solving the Furniture Industry’s Damaged Goods Dilemma

Furniture manufacturers face a common challenge; goods becoming damaged during transit.

The logistics of shipping bulky and irregularly shaped items often result in them arriving at their destination in less-than-ideal condition. However, a growing number of manufacturers are discovering a solution to this problem through investment in Right Size packaging technology, with companies like Panotec leading the charge.

The Damaged Goods Dilemma

For furniture manufacturers, damaged goods represent more than just a financial setback. They impact customer trust, harm brand reputation, and disrupt your supply chain. The nature of furniture, large, heavy, and often fragile makes it particularly susceptible to damage during transit. Traditional one-size-fits-all packaging methods often fall short of protecting these items, leading to an alarming rate of returns.

Right Size Packaging

Right Size packaging has changed the way furniture manufacturers approach packaging. Instead of using standardised boxes that leave unused space and excessive void filler, Right Size packaging involves customising packaging to fit each product’s exact dimensions. This tailored approach minimises wasted space, reduces the risk of product movement during transit, and enhances overall protection.

Who Are Panotec?

Panotec is a leader in automated packaging solutions, offering various systems that enable furniture manufacturers to optimise their packaging processes. By leveraging Panotec’s automated systems, manufacturers can produce custom-sized boxes on demand, ensuring that each item is packaged securely and efficiently. This not only reduces the likelihood of damage during transit but also streamlines operations and cuts down on material waste.

Benefits Beyond Damage Prevention

Investing in Right Size packaging with Panotec offers a host of benefits beyond mitigating damaged products. Manufacturers can enjoy cost savings through reduced shipping expenses and material usage. The efficiency gains achieved through automation enable companies to allocate resources more effectively, improving overall productivity and profitability. Additionally, embracing sustainable packaging practices aligns with consumer’s growing preference for eco-friendly brands.

Work with Ribble Packaging

Ribble Packaging has already been able to enhance the speed, accuracy, and cost-effectiveness of furniture packaging processes for the likes of Wren Kitchens, One Call Furniture, Magnet and BA Components to name but a few by adopting Right Size packaging with Panotec.

As the furniture industry continues to evolve, packaging will play an increasingly important role in shaping the customer experience. By prioritising investment in Right Size packaging technology, manufacturers can stay ahead of the curve and position themselves for long-term success.

If you would like to discuss the possibilities of Panotec, get in contact.

Why Packaging Waste Matters: New Extended Producer Responsibility (EPR) Updates

The way we package our goods can significantly contribute to a better planet, so it’s no surprise the spotlight is now on sustainability in packaging practices, with updated regulations on packaging waste set to come in October 2025.
These regulations come in the form of Extended Producer Responsibility (EPR), a regulatory framework aimed at changing how we approach packaging waste. Whether you’re sourcing materials domestically or relying on imports, this impending scheme is set to reshape your packaging operations.
This blog serves as an informative follow-up to our previous discussions on the topic, providing the latest updates on EPR.

Understanding EPR

At its core, EPR shifts the responsibility for packaging waste management onto producers, requiring them to bear the full cost of collection, sorting, treatment, and recycling. Recent updates to EPR regulations have brought about significant changes, including the introduction of modulated fees. The payment year has also been deferred from October 2024 to October 2025, however, businesses are still required to declare their packaging waste for 2023.
This initiative is driven by the objective of incentivising producers to limit packaging waste and enhance recyclability. This shift inevitably carries financial implications, as costs are predicted to increase. Therefore, it’s important to understand how EPR will influence your packaging operations and how you can proactively mitigate associated expenses.

Aligning Packaging Practices with EPR

EPR encourages producers to rethink packaging choices and design, urging businesses to embrace recyclable materials and eco-design principles while reducing waste. As companies gear up to comply with EPR regulations, it’s clear that innovative solutions will be essential in meeting these new standards effectively.

How can Right Size Packaging Help?

Right Size solutions combine Ribble’s industry-leading Fanfold material and state-of-the-art technology to create the perfect size box for all products. This ensures every item of packaging fits the product exactly, negating the need for void fillers and excess packaging.
We have a simple 4-step process for our Right Size solutions:
1. Enter box style and dimensions.
2. Select how many are required.
3. The box is produced within seconds.
4. Products are packaged in the perfect-sized box.

As well as saving on EPR tax, businesses will save on fuel and transport costs, regain warehouse space and save on labour costs, all resulting in up to 30% savings on packaging costs.
If you would like to discuss EPR in more detail with some of the packaging experts at Ribble Packaging, you can contact us at info@ribble-pack.co.uk or visit our contact page.

Print & POS Companies Deserve Better Packaging

Many print & POS companies are finding their hard work undone due to improper packaging.

Print and POS are often known for their creativity, but delivering exceptional work to clients extends beyond the ink on the page or setting up a sales display – it’s about ensuring that it arrives in pristine condition. The journey from print to delivery is often overlooked, yet it presents a significant opportunity to increase profits simply by embracing efficient packaging practices.

Why Efficient Packaging is Important

Efficient packaging serves as more than just a protective means during delivery, it should be considered an investment that saves time, money, and resources. By streamlining packaging processes, print and POS companies not only reduce the risk of damaged stock, but also reduce unnecessary expenses associated with overstocking and wasteful packaging materials. For instance, efficient packaging can lead to faster order fulfilment, reducing labour costs and improving customer satisfaction.

Additionally, companies embracing sustainable packaging practices not only return better cost savings but also contribute to a healthier planet, aligning with the growing pressures on corporate social responsibility. According to a recent study, just a 1% increase in CSR investments leads to a 0.3% increase in sales growth.

Right Size Packaging Solution

Right Size is the development of on demand packaging production. This technology enables companies to produce packaging precisely tailored to the dimensions of each product, eliminating the need for excessive filler or wasted space.

Working with Fanfold corrugated material offers the perfect solution to addressing the challenges of varied job sizes and delicate displays. With Right Size packaging, print & POS companies can begin to modernise their packaging operation and reduce expenditure.

Whether handling small scale print orders or large format POS displays, these solutions can adjust to accommodate various requirements allowing companies to innovate and expand their offerings. With the flexibility of Right Size solutions, you remain agile and responsive.

Ribble Packaging

By embracing Right Size packaging solutions print and POS companies can unlock substantial cost savings while delivering undamaged products to your clients.

Learn more about Ribble’s Right Size Packaging Solutions and how they can benefit your Print or POS business today. If you want to speak about your packaging needs in greater detail, call us on 0161 284 9000.

Packaging Processes Have Moved On, Have You?

Automation is everywhere these days, from self-driving cars to smart home devices, it seems like we’re all on a mission to make life a little easier. Which asks the question, when was the last time you reviewed your packaging process? And could you benefit from exploring the new automated capabilities they now hold?

Packaging Automation

Automation can be implemented across various stages of the packaging process, from box forming to labelling and palletising. The idea is to only get what you need, starting small with automation modules and expanding as needed, allowing for growth and adaptation to your changing business requirements.

Each Stage at a Glance

Measuring Station: Using sensors to measure dimension and weight.

Box Production: Corrugated or die-cutters will cut, fold and glue your box into the desired shape.

Box Forming: Taking flat card and shaping it into the desired form.

Coupling Box and Product: Utilising pick and place machines, robotic arms, or conveyor belts to handle the product in position.

Box Closing: Sealing the box securely.

Labelling: With sensors and actuators attached as predetermined.

Palletising: Stacking boxes onto pallets in a certain pattern, often with a control system to optimise the stack.

Benefits of Packaging Automation

Firstly, automation leads to substantial labour savings by reducing the need for manual intervention in packaging processes. This not only cuts down on labour costs but also minimises the risk of human error, resulting in higher quality outputs and reduced wastage, saving multiple costs around the business.

Automation will also drive increased productivity by enabling packaging processes to run faster and more consistently. Tasks that once took hours to complete can now be accomplished in a fraction of the time, helping to meet tight deadlines and customer demands with ease.

Is Automation Right for You?

Before you take the automation plunge, it’s worth taking stock of where you stand. Assess factors such as production volume, product variability, and budget. Conducting a thorough analysis of these factors can help determine the potential return on investment (ROI) of purchasing an automation packaging machinery and justify the initial investment costs.

Ribble Packaging are here to help

By leveraging packaging automation, businesses like yours can reap the benefits of packaging automation and achieve significant cost savings, improve productivity, and deliver higher quality products to customers. So why wait? Take the first step towards streamlining your packaging processes today.

If you want to speak about your packaging needs in greater detail, get in contact or call us at Ribble Packaging on 0161 284 9000. With over 80 years of packaging expertise, we help streamline your packaging processes to reduce waste and restore profits.

Bulk Buying Doesn’t Always Mean Savings

The way products are packaged can significantly impact a company’s bottom line, and for years the go-to strategy has been bulk buying both packaging materials and void filler, but what many fail to realise are the hidden costs associated with this traditional approach.

Rethinking Bulk Buying

Bulk buying packaging materials has long been the default option for many companies due to the attractive discounts offered on larger quantities. Yet, this seemingly cost-effective strategy may be putting a strain on your warehouse space. Worse yet, if you cater to many different sized products, your packaging can sit for long periods of time.

However, there is a more efficient and cost-effective way to approach your packaging…

Getting it Right First Time

Investing in Right Size packaging solutions can significantly reduce packaging costs by up to 40%. It is already being utilised by various industries, from furniture to manufacturing. This approach is centred on efficiency and cost-effectiveness, as companies use rolls of fanfold cardboard that adapt to different product shapes and sizes seamlessly.

This works by scanning and entering the box style and dimensions, selecting the quantity required then your box is produced within seconds. With this precise customisation, it allows for the perfect sized box every time, eliminating any need for void filler, meaning less clutter and the opportunity to optimise your warehouse space.

Real Packaging Cost Savings

One of our clients, BG Sports, struggled with their packaging as they shipped sports memorabilia in all different shapes and sizes. Bulk buying packaging was inefficient and ordering smaller quantities was too expensive. With the business growing, space started to become an issue, and that’s why they invested in Right Size solutions. They achieved a significant reduction in packaging material usage and storage costs, reducing their packaging bill from £400k a year down to £200k, thanks to the adoption of Ribble’s Right Size. Read more about their story here.

The benefits of Right Size packaging extend beyond this case study. It also reduces material wastage, lowers shipping expenses, decreases product damage and returns, maximises shipping capacity, and helps businesses adapt to price increases in the supply chain. Companies that adopt this approach not only contribute to environmental sustainability but also witness a positive impact on their bottom line, making it a win-win solution.

Choosing Ribble Packaging

As businesses reassess their packaging strategies, we encourage you to explore the many costs saving benefits with Right Size solutions. At Ribble Packaging, we specialise in providing tailored solutions that align with your business needs. Contact us today on 0161 284 9000.

Transforming Furniture Packaging with Panotec Automation

Furniture manufacturers are constantly seeking ways to boost efficiency and reduce costs, yet surprisingly, the packaging process often gets overlooked.

Countless furniture manufacturers are currently grappling with a range of packaging problems that not only impact their operational efficiency but also have significant financial implications. Perhaps the most pressing concern among these challenges is the need to prevent transit damage. When your furniture arrives at its destinations in less than perfect condition, the costs incurred can be hindering, not just in financial terms, but also in terms of the reputation of your company. As much as 11% of unit loads arriving at a distribution centre have some level of packaging damage.

Adding to this is the reliance on traditional packaging methods that have long been in use within the industry. These conventional approaches, while deeply ingrained, often prove to be surprisingly wasteful. They also may demand a significant level of skill from your employees, presenting yet another challenge. Whilst these are just a few of the common faults from across the industry, it shows how important it can be to ensure your packaging quality remains consistent while packaging a wide array of different furniture, whether it’s antique dining sets, flatpacks, or large beds.

The Need for Innovation

To overcome these challenges, manufacturers often turn their attention to automated packaging solutions.

The industry is vastly adopting automated solutions, and the initial concerns surrounding quality and adaptability have been removed. Leading machinery, such as Panotec automation, now offers innovative solutions that transform the way furniture is packaged.

One of the key advantages of automation is its ability to reduce the need for specialised skills in furniture packaging. The automated processes make it accessible to a wider range of operators, with minimal training. This not only simplifies the process but also addresses the issue of skilled labour shortages, which has been a growing concern in the manufacturing industry with statistics from ONS showing manufacturing vacancies are still higher than pre-pandemic.

Transition to Automation

Manufacturers can start by assessing their current packaging processes and identifying pain points. This initial step provides a clear understanding of where automation can make the most significant impact. Once the areas in need of improvement are identified, manufacturers should research and choose the right automation solution for their specific needs.

Customisation and Flexibility

One of the key advantages of automation in furniture packaging is the ability to customise solutions to meet the unique requirements of each manufacturer. This flexibility means that manufacturers that use automated packaging systems no longer need to rely on one-size-fits-all packaging.

Quality Assurance

Quality assurance is at the heart of any manufacturing process, and automated packaging solutions are designed to excel in quality control while reducing the potential for human error. With Panotec automation, furniture manufacturers can enhance their efficiency and reduce costs while maintaining the quality and reputation of their brand with consistent packaging.

This technology is a new era of furniture packaging, and manufacturers who embrace it will be well positioned for future growth and upcoming trends. If you want to speak about your packaging needs in greater detail, call us at Ribble Packaging on 0161 284 9000. With over 80 years of packaging expertise, we help streamline your packaging processes to reduce waste and restore profits.

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