Tag: Right Size

Sustainable Packaging Solutions for Made-to-Order Businesses

Posted on by definitionconsulting

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.

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

Posted on by definitionconsulting

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)​​.

Solving the Furniture Industry’s Damaged Goods Dilemma

Posted on by definitionconsulting

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

Posted on by definitionconsulting

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

Posted on by definitionconsulting

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.

Bulk Buying Doesn’t Always Mean Savings

Posted on by definitionconsulting

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.

BG Sports

Posted on by wecreatedm

BG Sports are a licensed sports memorabilia company who have licences with most Formula 1 teams, UFC and Anthony Joshua, with many more on the way. Memorabilia is produced in house along with the manufacture of F1 show cars and driving simulators.

With the business growing, space started to become an issue and given the large variety of shapes and sizes of products, packaging SKU reductions became a necessity. BG Sports researched the right solution for their operational needs and found it with Ribble Right Size.

“Before we bought the machine we would spend around £400,000 on boxes and now we have cut that down to £200,000, that’s just in our first 12 months.”

“The most important thing it has helped us with is making packaging on demand, we can make a one off box for a random size parcel compared to before where we would need to get a quote, order the MOQ and wait for delivery to package specific size products.”

“We chose Ribble after doing some research and they were the best priced on the market. They are a one stop shop with the supply of Fanfold and we get great customer service.”

Are your shipping costs getting out of control?

Posted on by definitionconsulting

Reduce your overheads with Right Size packaging!

If you are looking to reduce your overheads, one often overlooked aspect of cost reduction is the choice of packaging, according to a study by the Guardian, oversized packaging leads to five million unnecessary delivery journeys every year. By adopting the principle of Right Size packaging, businesses can achieve significant savings in multiple areas.

For any business involved in transporting, handling, or storing products, adopting packaging solutions that perfectly fit your products can lead to a multitude of advantages.

Right Size packaging means fewer material costs, which then means fewer production costs and handling fees. It also results in a reduction of transport costs as more packages can fit on a pallet, or cheaper parcel brackets if you’re sending individual products. And finally, you can store more products for less, which also increases your buffer stock, building a more resilient supply chain.

How have we got to this point with excess packaging? Businesses often buy large volumes of stock packaging to reduce unit costs. This means they have just a few packaging options for all their products. This results in products being shipped in the nearest fitting packaging, regardless of their size. This practice is expensive and wasteful.

 

The benefits of Right Size

  1. Cost-Effective Shipping

The primary and most immediate benefit of Right Size packaging is cost effective shipping. When the packaging matches the exact dimensions and weight of the products, businesses eliminate the expense of excess materials. This translates into significant savings on shipping costs.

  1. Enhanced Storage Efficiency

Every square inch of storage space matters, especially in growing businesses. With Right Size solutions, businesses can maximise their warehouse space by using packaging that fits their products precisely. This optimisation means fewer trips to replenish stock, reducing labour costs and enhancing storage space utilisation.

  1. Efficient Transportation

Efficiency in transportation is a key driver of cost savings. Right Size packaging increases the density of products within each shipment, making the most of the available space in trucks, containers, and cargo holds. This means fewer trips and less fuel consumption.

  1. Minimised Damage and Returns

Oversized packaging often leads to products shifting and getting damaged during transit. By using Right Size packaging, products remain secure, and the risk of damage is greatly reduced. This not only cuts the cost associated with damaged goods but also lowers the number of product returns, saving money on shipping and restocking.

  1. Streamlined Handling

Efficient handling of packages is a critical aspect of logistics. Right Size packaging simplifies the loading and unloading process, eliminating the need for excessive handling. This not only saves time and labour during each shipment but also optimises workflow, resulting in reduced labour expenses and increased productivity.

 

How Ribble can help?

Adopting Ribble Right Size solutions can have a transformative impact on shipping and logistics, it’s the most effective and efficient packaging for your product.

Whether you are a manufacturer of one product or a retailer of many, it significantly reduces your overheads and shipping costs, optimises storage and transportation efficiency, and minimises damage and returns.

Ribble’s Right Size solutions combine industry leading Fanfold material and state of the art technology to create the perfect size box for all your products.

By prioritising Right Size packaging in your logistics operations, your business can unlock a host of benefits that ultimately contribute to long-term success and cost savings in a highly competitive environment.

Evergreen Shutters

Posted on by wecreatedm

Herefordshire based Evergreen Shutters are a manufacturer of bespoke shutters for domestic applications. All shutters are manufactured in the UK and painted in house.

As all products are made to measure, packaging each item securely became difficult and a change was needed to eliminate transit damage and customer satisfaction. After many attempts to find the perfect packaging solution for their products they chose Ribble Right Size, a flexible on demand packaging solution that allows each product to be packaged in the perfect size box.

Evergreen Shutters Associate MD, Richard Jenner said:

“The problem that we were experiencing is that shutters are a premium product but as they are made to measure we were struggling to find a packaging solution the matched the premium nature of the product. We came across Ribble who helped us with a creased Fanfold solution to start with before the option of a Right Size solution. They helped us to design the best solution from the right board grades to the inclusion of added buffer zones for increased protection, so really it was the best solution for us.”

“The service and products from Ribble have been exceptional. The beauty of switching to the made to measure solution has meant that we have been able to simplify our number of packaging SKU’s down to just 2 lines of Fanfold, so much similar that what we were doing previously. Really simple and straightforward, its everything we could want from a packaging supplier.”

Pivot

Posted on by wecreatedm

PIVOT manufacture a bed that turns into an all-in-one home gym in a matter of seconds. The bed provides the perfect solution for people who cannot easily access a Gym due to their location or who want to workout at home but lack the space for a separate home gym. PIVOT’s unique product has proven a hit both in the UK and abroad with North America and Europe seeing increased sales year on year.

Given the size of their product, PIVOT struggled to find a suitable packaging solution for the multiple boxes they required to fulfil each order. With a relatively small number of orders and wide variety of box sizes required for each order, die-cut boxes would not have been a viable solution due to supplier minimum order quantities and available warehouse space.

With Ribble Right Size, PIVOT have been able to create a packaging process that adapts to all of their requirements, allowing each part of their order to be sent out in the perfect size box, on demand. Right Size has allowed PIVOT to optimise their packaging for every part, so that every bed can be sent out tightly and securely, preventing any damage during shipping.

PIVOT CEO, Colin Montgomery said:

“Being a UK company with a strong desire to work with other UK companies, when we found Ribble and the Panotec system it just felt right. We met them, immediately liked the people and felt like they had a true desire to help us. And we needed that help way back then, let’s be clear! The fact that they’re based in the North of England, like we are, is also a help as we know we’re covered by their delivery and support reach.

Ribble are very friendly, professional and helpful. They’ve always been quick to respond to our questions and requests. Their engineering team have been incredibly supportive and we’ve felt well taken care of by the sales/accounts team. They’re our only supplier to have proactively reduced pricing since we started.”

Copyright © Ribble Packaging Ltd.