Evergreen Shutters

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

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.”

How to reduce your packaging spend when prices are going up

With prices rising throughout the supply chain, many companies will be looking for ways to help reduce costs. One way businesses can do this is through their packaging costs.

When did you last review why you are using the packaging design and components that you are using? Do you need all of the components you are currently using?  Is there a better way to package this product?

Challenging your current packaging design can result in large potential savings, the packaging market is very dynamic and as a result new materials and systems are being launched regularly.  By sticking with the status-quo you risk losing out on savings that could be made by changing to a more cost-effective packaging design.

What items can you eliminate from your packaging process?  Often extra packaging is added to items to compensate for an underlying root problem.  This is neither a lean nor cost effective solution.  Analysing the process may identify unnecessary packaging items within your packaging.

Reduce your packaging costs by changing to a Right-Size packaging solution

Whether you are a manufacturer of one product or a retailer of many, using Right Size packaging allows you to create a more sustainable packaging process while reducing your packaging costs.
Right Size solutions combine Ribble’s industry leading Fanfold material and state of the art technology to create the perfect size box for all your products.

This product is flexible, cost-effective and can be converted into Fanfold packaging which is a long piece of corrugated board scored at regular intervals and folded neatly and compactly. Fanfold can then be used to pack single or multiple products by feeding it into fully automated packaging machines to create an exact size box and therefore, eliminate waste.

Ribble Packaging are the European market leader for the manufacture and supply of corrugated Fanfold, in addition to pioneering Right Size packaging solutions in the UK.

Benefits of changing to a Right-Size packaging solution:

  • Save around 30-40% on packaging costs by using Right Size and only buying fanfold
  • Eliminate obsolete packaging purchases by making only the boxes you require
  • Eliminate plastic packaging by using the Right Size box
  • Reduce transport costs by fitting more onto vehicles

How Ribble can help?

At Ribble, our Right Size packaging can help your business save money, plastic packaging, and transport costs. Contact us today to see how our packaging can benefit your business.

How Right Size Technology can save you thousands on fuel and energy costs

In 2020 1.27 billion tonnes of goods were carried by trucks and HGVs across the UK, covering 16.2 billion road miles.

Due recent socioeconomic and political factors the cost to fuel these HGVs has risen by £173 per week. Diesel has hit a record high of £1.70 per litre, while petrol now costs an average of £1.61 per litre.

With fuel and energy costs soaring; Inflation is at its highest level for over 30 years, with much of these rises passed onto the consumer as firms simply cannot absorb such significant increases (Elizabeth de Jong, Logistics UK).

 

What’s Happening Now?

Fuel accounts for a third of an HGV’s annual operating cost.”  So ‘The Road Haulage Association’ wants the Government to freeze fuel duty for two years. It also wants an “essential user” rebate for lorry and coach firms of 15p per litre introduced.

Rising fuel prices are putting further pressure on retail supply chains. This adds to cost pressures from labour shortages, commodity price increases and rising energy prices in consequence, until some pressures ease, it’s likely prices will continue to rise.

Meanwhile, analysis shows the annual average cost of running a typical family car, including fuel, has shot up by nearly £300. Many consumers are having to choose between purchasing food, heating their homes or putting petrol in their cars.

 

How Ribble Right Size Can Help?

Many people overlook the importance of packaging when it comes to shipping goods, but an efficient and effective packaging supply is essential to keeping the product safe and most importantly keeping customers happy.

Ribble Right Size solutions improve vehicle utilisation by 25%. This means companies who have implemented Right Size can fit 25% more product in each vehicle drastically decreasing fuel consumption.

By Right Sizing your packaging supply you will gain the ability to create the perfect size box for all your products on-site, on-demand, eliminating any wasted space in your packages and therefore any wasted space in your transport vehicle.

With Right Size there is no need for additional protective packaging materials such as bubble wrap or Styrofoam peanuts as your boxes will now fit your products perfectly, increasing product protection, decreasing the weight of your packages, and making your packaging process fully sustainable.

There are also many other benefits of using our Right Size solutions. These include up to a 30% reduction in packaging costs, savings on labour costs through increased automation, increased warehouse space and more.

Every cubic inch of your packaging that doesn’t contain your product is costing you money. By introducing Right Size Technology, you can get more boxes in each vehicle, meaning fewer journeys and less money spent on fuel and diesel.

 

How to eliminate plastic packaging from your business

Now that the plastic packaging tax has come into effect, many businesses should be thinking about ways to reduce or eliminate plastic packaging. Getting rid of plastics from your business’ everyday practices can make a huge impact, and it’s easy to do with a few small changes.

Many businesses find that amending their policies is a powerful way to reduce single-use plastics. This might include asking suppliers to pack without plastic and requesting reusable, returnable, or sustainable packaging such as recycled cardboard boxes or ‘jackets’ to replace plastic wrap on pallets.

If that’s not possible, you might want to look beyond your current suppliers and see if there are others out there offering more sustainable packaging and solutions.

When it comes to doing business, you can make a difference by offering reused packaging to your customers. For example, some retailers keep cardboard boxes on hand for customers who forget their bags instead of throwing them away. Some companies that ship orders use shredded paper to protect products instead of bubble wrap.

 

The alternatives to plastic packaging

There are also many alternatives to plastic packaging. Anything that a business does to become more sustainable is ultimately helpful. This is particularly true with bubble wrap, as there are many alternatives that your business can use. Some alternatives include:

  • Compostable mailers
  • Corrugated packaging
  • Biodegradable packing peanuts
  • Mushroom packaging
  • Seaweed packaging
  • GreenWrap

There are more than these, and many of them can be reused or recycled, so they are kept in use for longer and help reduce waste.

 

Ribble’s solution to plastic packaging

Ribble also has ways to eliminate or at least reduce plastic packaging. Our Right Size packaging is an easy way to reduce the amount of packaging you use, and therefore reduce the amount of waste. Right Size solutions combine Ribble’s industry leading Fanfold material and state of the art technology to create the perfect size box for all your products.

We have a simple 4-step process for our Right Size solutions.

  1. Enter your box style and dimensions.
  2. Select how many you require.
  3. The box is produced within seconds.
  4. Your products are packaged in the perfect sized box.

There are also various benefits of using our Right Size solutions. These include up to 30% reduction in packaging costs, labour saving, increased warehouse space, elimination of void fillers, and more.

 

To find out more about how Ribble’s Right Size solutions can help your business reduce or eliminate its plastic packaging usage, contact us today.

Flexibility is Key With Right Size Solutions

Having worked at Ribble for two years in the marketing department, about six months ago I had the wonderful opportunity to move into a new role as Business Development Manager. A very exciting change, and I couldn’t wait to take a crack at selling Right Size automated packaging solutions – something I had been marketing for the last two years.

Right Size solutions is a packaging process which allows the customer to create the perfect size box, on demand, in house. One thing I have found when talking to prospective customers, is the versatility and flexibility of the machines is often one of the most attractive aspects of the solution and probably the most underestimated. They are surprised to hear how this machine can offer 40 different styles of box, in any size required, in addition to the option for bespoke designs. Not to mention the fact you can create any box whenever you need it, whether it is 1 box or 1000. Just imagine, an urgent/unexpected order comes through and there’s no need to wait for supplier lead times, no adhering to MOQs – just pop your requirements into the Panotec machine and out comes exactly what you need, when you need it. The power of flexibility cannot be understated. When combined with all the other benefits of Right Sizing, the solution becomes a no brainer in my opinion.

  • Reduces your annual corrugated spend (generally by 20-30%)
  • Eliminates the need to stockpile boxes which are the wrong size for your product
  • Improves vehicle utilization by up to 25%
  • Saves huge labour costs
  • Hugely reduces the requirement for void fillers and other plastic packaging
  • Creates an environmentally sustainable packaging process

It is fair to say that over the past year, every business will have seen huge changes in the way they operate. We have all had to adapt to the everchanging situation whether that is supply chain issues, unexpected peaks and troughs in demand, or labour concerns. Having a packaging solution which has the versatility to adapt in unprecedented conditions has been key for so many of our customers. It has given them the control they need to navigate these tricky times.

At risk of repeating myself, the importance of flexibility should not be understated. I am sure every salesperson has their go to spiel they use to impress clients, and this is quickly becoming mine! It has been incredibly exciting working in my new role, and what a time to be in the corrugated packaging industry. The pandemic has catapulted sustainable, corrugated packaging to the forefront with a huge boost in demand from Ecommerce. Since I have been part of the company, Ribble has made some huge changes to keep up with this demand, including a £6 million investment to our Oldham site throughout 2020/21. Not to mention, further investment projects which are lined up over the coming years – and one biggie in particular to keep your eyes peeled for going forward… Watch this space!

Protective & sustainable packaging

Have you ever thought about how much excess packaging comes with new furniture?

The truth is that sometimes we get more than we need, and it’s understandable because the manufacturer only includes the extra foam, bubble wrap or tissue paper to protect the items whilst in transit to their destination. However, Right Size solutions offer a more effective and sustainable alternative to furniture packaging.

What are the Ribble Right Size solutions?

Right Size solutions enable the customisation and creation of the correct sized box for pieces of furniture.

Create protective and sustainable furniture packaging.

At Ribble Packaging, not only is our priority creating packaging that is kind to the environment, we also create packaging that protects the products inside. With custom made, recycled fittings that are placed around the product inside, customers can rest assured that their product will arrive to them safely.

The secure and protective fittings mean that products arrive at their destination, undamaged while still reducing excess fillings and saving space.

Perfect-sized boxes are created within minutes using Ribble’s fanfold corrugated board and Panotec machine technology.

The box on-demand service can be installed on-site and gives manufacturers a choice to input the size of the product manually or automatically through a barcode or a 3D scanner system.

Additionally, manufacturers can enter the works order to ensure the correct number of boxes is made for the particular piece of furniture.

What are the benefits of using Right Size?

No more excess packaging 

Right Size packaging will protect assembled or flat-pack furniture, which removes the need to add unnecessary and excessive protective fillers, including plastic cushioning material, ultimately creating a 100% recyclable packaging process for all your furniture products.

Savings on packaging costs 

Right Size solutions can create a 30% saving on packaging costs and remove the need to fill minimum order quantities from suppliers. Furthermore, the box on-demand creates the perfect-size box every time, so there is no longer the need to stock-pile wrong sized boxes.

Customer satisfaction 

Presenting customers with the perfect-sized, 100% recyclable packaging for their furniture is sure to put a smile on their faces, in addition to showing that you are taking steps to fulfil your corporate social responsibilities.

If you’d like more information on how you could save up to 30% on your packaging costs, get in touch with us today.

Packaging in 2022 – The key solutions for the New Year

Since the beginning of the pandemic, retail has seen a significant shift to ecommerce shopping methods. With that brings increased need for additional packaging when transporting and shipping goods.

As a result, this will continue to increase the need for more sustainable and environmentally friendly packaging solutions.

We have been exploring the key packaging solutions that we believe will become increasingly popular in the new year.

Packaging Automation

With COVID 19 continuing to be a threat across the globe, the automation of packaging will continue to be important for many manufacturers and distributors. This will reduce the amount of workers needed within one space and overall costs to the business too.

Not only that, automating your process will allow the business to increase their targets, which will continue to improve efficiency.

Ecommerce Packaging

The shift in consumer behaviour since the beginning of the pandemic is highly unlikely to ever return to pre-COVID levels. As a result, consumers will continue to expect a smooth and flawless experience – from browsing their purchase to placing their order and its delivery.

This means every detail, right down to the packaging must impress. Consumers are aware of the environmental issues facing the planet and with that they expect to see changes to the ways in which their goods are packaged and delivered to them. Reducing unnecessary and excess packaging is a crucial step in that process.

Reusable Packaging

Reusable packaging has become very popular in recent years and can be seen in more and more shapes and forms. Whether that is reusable plastic for cleaning products or paper bags that can also be used as wrapping paper.

When packaging isn’t necessarily reusable, it is important for consumers that it is made from recycled materials or can be recycled once used.

Ribble Right Size

At Ribble our Right Size Packaging solutions allows you to reduce excess packaging and create a sustainable alternative that reduces costs by creating custom packaging solutions to meet your needs. We use 100% recycled cardboard that is 100% recyclable, meaning it is the perfect sustainable solution.

The benefits for choosing Right Size can be seen in the reduced need for void fillers within your boxes due to the packaging being custom created for whatever you are distributing; you can improve your vehicle utilisation by up to 25% and the creation of a more environmentally sustainable packaging process.

Get in touch today to discuss how Right Size can improve your business packaging solutions.

How I discovered the Right Size solution for returns management

I joined Ribble Packaging in April 2021 as a Business Development Manager with a primary objective to sell Panotec automated box making machines and Fanfold corrugated board.

The moment I investigated the type of machinery I would be offering, I was sold. A machine, that produces the perfect size box, within a matter of seconds, on site, on demand? Where can I buy one of these for my garage?! I could instantly see the benefit and asked myself ‘why have I never heard of this before, its genius!’

After my induction and training, I was allocated a handful of accounts to manage, including a number of high-profile retailers. I was surprised, shocked, and intrigued when I heard some used their Panotec box maker solely to package returned product, ready for re-sale. My mind started to wander. I visited one of their sites to see their operation firsthand and was very impressed. They use the Panotec bar code scanning system. This means they input the dimensions and sizes of the box they require and marry that up with the product bar code. They now have a database of hundreds of products which, with the scan of a bar code, can replicate the same box style almost immediately.

This got me thinking, what normally happens to these returns? Well, after a small amount of research, the options became very clear. Either: order new packaging, send back to be re-boxed, send to landfill or palletize with other products and sell on to someone who will try and a make a pound or two (often making a YouTube video titled: I bought this pallet full of returns & made £££££) either way, companies are loosing a vast amount money.

Ribble also work with a manufacturer who also use their machine solely for returns. This company have saved over £250,000 in their first few months of using their Panotec machine.

Now, when I speak with prospective clients, returns are always something I’ll discuss. Not only can Right Size revolutionize the way you handle returns, it also:

  • Reduces your annual corrugated spend (generally by 20-30%).
  • Eliminates the need to stockpile boxes which are the wrong size for your product.
  • Improves vehicle utilization by up to 25%.
  • Saves huge labour costs.
  • Hugely reduces the requirement for void fillers and other plastic packaging
  • Creates an environmentally sustainable packaging process.

Often, the return on investment for one of our machines is only a couple of years. Ribble will work with you to optimize the way you package. We can also offer several payment options to suit your businesses individual requirements.

For the company I mentioned earlier, they have generated an additional £250,000 in only a couple of months. This means their machine has paid for itself twice over, they have reduced the amount of product going to landfill and taken full control over their packaging.

Does this all sound too good to be true?!?!  Well, I can assure you it’s not, and that’s the exact reason I took the job back in April. Ribble are a hugely credible company, with oodles of experience and a history of manufacturing cardboard since 1938. I am now pleased to be a part of their heritage.

Frequently Asked Questions about Right Size Solutions

Frequently Asked Questions about Right Size Solutions

 

As experts in Right Size Packaging, we get lots of questions from people who are interested in switching. So, we thought we’d cover the basics here and let you find out for yourself if Right Size Packaging is right for you…

 

How much does Right Size Packaging cost?

 

This is our number one question when we have a prospective customer, but the truth is – it’s not an easy one. There is no set answer as it is very dependable on what industry you work in, type of machine required and the way in which you acquire the machine. At Ribble Packaging, we offer various ways of acquiring the machine including (but not limited to) rentals, amortise and connect deals, in addition to purchasing the machines outright.

 

How many boxes can be produced per minute?

 

Right-sized boxes per minute will depend on the model of the Panotec machine you opt for. Please see below our latest estimations.

 

Nextpro – Approx. 10 boxes per minute

Evo – Approx. 4 boxes per minute

Midi – Approx. 4 boxes per minute

 

How many people are required in the warehouse to manage the system?

 

All of our Panotec machines can be run by just one operator. For a trainee operator, the process of loading a pallet, feeding the fanfold into the machine and producing a box, can be achieved in just a few minutes!

 

Depending on your business and if you choose to add on any additional automated extras such as the Scan table, E-Gluer, and Varypack, then more operators could make the process quicker and more efficient.

 

How much warehouse space will a Right Size Packaging system need?

 

Business Directors and Production Managers often worry that having a flexible packaging management system will require tonnes of space. But the truth is, you’ll actually save space by not having to store multiple shapes and sizes of packaging materials. Listed below are the approximate space requirements depending on which Panotec model you choose.

 

Nextpro operating width – 2.5m

Evo operating width – 2.5m

Midi operating width – 1.4m

 

Each machine will have different a different number of cassettes. These are essentially bays for the pallets to go in. Depending on your business requirements, this will be optimised for maximum production.

Right Size Packaging is perfect for businesses that sell products of all different shapes and sizes. By having customisable boxes on demand, companies can reduce the costs of storing packaging and benefit from having no additional filling material to purchase.

 

If you think Right Size Packaging could be for you or you have a question that we haven’t covered here, please get in touch.

Copyright © Ribble Packaging Ltd.
Designed by Definition Consulting