Category: Blog

Right Size Packaging for Large Businesses That Cuts Costs, Waste and Space

Posted on by definitionconsulting

Look inside many warehouses and you’ll still see boxes that are far bigger than the products they hold. They’re padded with loose void fill, stacked inefficiently and shipped at inflated rates because carriers charge for space as well as weight. It’s a slow, expensive bleed across procurement, warehousing and transport — and it’s completely avoidable. Right Size packaging shows that less really is more.

Why oversized packaging is quietly expensive

Oversized boxes create costs at every touchpoint. They increase dimensional shipping charges, use more corrugated board than necessary, reduce pallet and racking density, and often mean extra handling. Those “small” inefficiencies compound into meaningful spend for large-volume shippers.

Cut shipping costs by removing wasted space

Carriers bill by volume as well as weight. A box that’s even one size too big can push a parcel into a higher band and multiply costs across thousands of shipments. Right Size packaging reduces that wasted air, lets you fit more units per van or pallet and lowers transport costs per item.

Use less material and reclaim storage space

On-demand, product-fit boxes reduce corrugated use and remove the need to stock dozens of standard sizes. Fewer box sizes, less void fillers and smaller dimensions free up pallet and shelf space so you can store more finished goods in the same footprint and slow the growth of warehousing costs.

Protect products better and cut returns

When products sit tightly in a box, they’re far less likely to shift, even without bulky plastic fillers. Better fitting boxes reduce transit damage, lower return rates and protect brand reputation.

Meet sustainability goals with smarter materials

Right Size packaging pairs naturally with recyclable fanfold corrugated board to reduce waste and reliance on single‑use plastics. Smaller boxes mean fewer lorry trips and less packaging waste overall, helping sustainability targets without compromising performance.

Automation: how on-demand boxes fit into busy packing lines

Making Right Size packaging viable at scale depends on automation. Integrated box-making systems produce single-piece boxes on demand at the pack station, removing box overstock, cutting changeover complexity and delivering consistent, repeatable packaging quality. They’re designed to slot into existing conveyor and packing workflows and scale with throughput.

Real benefits you can measure

  • Lower per-parcel transport charges through reduced dimensional weight billing
  • Reduced corrugated spend and less void fill in use
  • Improved storage density and fewer delivery trips
  • Fewer product damages and lower return handling costs

See what Right Size packaging could do for you

If you’re reviewing packaging and want to cut costs, looking to improve warehouse efficiency or aiming to hit sustainability targets, Ribble Packaging can help. Request a free Right Size savings estimate and find out how smaller, smarter boxes can transform your operation.

Strategies to Achieve Cost Efficiencies Across Your Packaging Process

Posted on by definitionconsulting

If you’re reviewing costs across your supply chain, packaging is an area that can get overlooked. It’s more than just boxes and tape. The right setup can reduce warehouse storage, increase throughput, lower shipping rates and even reduce the chance of returns. Done properly, packaging becomes a performance driver, not just a cost.

At Ribble Packaging we work with large businesses to help simplify, automate and improve the efficiency of their packaging operations. Based on what we’ve seen across sectors like furniture, retail, print and manufacturing, here are four strategies that deliver measurable cost savings.

  1. Optimise packaging inventory to reduce warehouse space

Excess packaging stock takes up valuable warehouse space and ties up cash in materials you may not use. If you’re relying on one-size-fits-all boxes or pre-made packaging held in bulk, that space pressure adds up quickly.

A better approach is to produce packaging on demand. Using fanfold corrugated board and Panotec machinery, it’s possible to make the right size box exactly when you need it. This removes the need to store dozens of box sizes and cuts down the space needed for packaging inventory. For larger operations, it also opens up the opportunity to reallocate that space to higher-margin activity.

  1. Reduce labour costs while gaining productivity

Manual packaging processes are time-consuming and inconsistent. Switching to an automated packaging line reduces the labour intensity while increasing the number of units you can process per hour.

On-demand packaging systems support full automation, including measuring, box creation, forming, sealing, labelling and palletising. This reduces the likelihood of human error and creates a consistent workflow that scales up as volumes increase.

  1. Lower shipping costs with Right Size packaging

Oversized packaging doesn’t just waste materials, but it can also increase your shipping costs. Most carriers charge based on dimensional weight, which means empty space in a box often costs as much to send as the product itself.

By switching to Right Size packaging, you reduce the size and weight of each parcel. This improves truck and pallet utilisation, lowers your average cost per shipment and reduces the carbon footprint associated with your outbound logistics.

  1. Minimise return costs by preventing transit damage

Returns are expensive and inconvenient for everyone involved. Processing them takes time and damaged goods often can’t be resold. If your current packaging isn’t well matched to the size and fragility of your product, it increases the risk of damage in transit.

With custom fit packaging made on demand, products are held more securely, meaning fewer breakages, fewer complaints and a more consistent customer experience. It also reduces the need for plastic void fillers or bubble wrap, helping you meet sustainability goals under the new EPR update while making disposal easier for the end user.

Talk to Ribble about cost-effective packaging

For large businesses under pressure to reduce costs, packaging is an area worth rethinking. Ribble Packaging work closely with businesses across the UK to help implement smarter packaging solutions using 100% recycled and recyclable materials. Our goal is simple: help you reduce waste, lower costs and make packaging one less thing to worry about.

If you’re looking at ways to improve your packaging operation, we’re here to help. Contact our team to discuss your setup or learn more about Right Size packaging and Panotec automation via our website.

Ribble Packaging: The Team Behind Smarter Packaging Solutions

Posted on by definitionconsulting

If you’re reviewing packaging costs, cutting down waste, or trying to make sustainability part of how your business operates, you’ll want to know who you’re working with.

Ribble Packaging has worked with large UK businesses for decades. We don’t overpromise or rely on gimmicks. We focus on helping you reduce cost, space, and environmental impact through packaging that’s practical, tailored, and well supported.

Here’s a clear view of who we are, what we do, and why it works.

A bit about us

Ribble has been producing corrugated packaging since 1938. Today, we’re focused on helping large businesses use sustainable packaging solutions that also improve efficiency.

We specialise in fanfold corrugated board, which supports automated production of Right Size boxes on demand. This means your packaging fits your products exactly, using less space, fewer materials, and no unnecessary filler.

What we do differently

Most packaging suppliers sell you a product. Ribble works more like a partner. We help you understand the link between your packaging and your operational performance. Then we support you in making that change.

Businesses come to us because they want:

  • More control over packaging output and costs
  • Less waste in transport and production
  • Less storage taken up by oversized packaging
  • Clearer data for sustainability reporting

We help with all of that, using proven technology and teams who know what they’re doing.

One of the key ways we do this is through our partnership with Panotec, a leading provider of on-demand box-making machinery. These systems integrate with your workflow, allowing you to automate the entire packaging process, from measuring the item to producing and forming the box, coupling it with the product, closing, labelling and palletising.

With three machine options, depending on your output requirements, whether you’re shipping 50 items a day or 5,000, Panotec machines paired with Ribble’s fanfold corrugated board offer you flexibility, speed and savings without unnecessary material usage or wasted space.

The teams behind Ribble

We’re able to support large, complex organisations because of the people behind our product. Working in sectors like furniture, retail, print/POS, kitchen and bathrooms, and manufacturing.

Production

Our manufacturing site in the North West is set up to handle high volume, high quality production. We’ve invested heavily in our fanfold lines and corrugating equipment so we can deliver consistently, with short lead times.

Sales

This isn’t a hard-sell team. Our salespeople are packaging experts who understand the operational side of business. They’ll work with you to make sure our setup fits yours, from the volumes you need to the machinery you use.

Support

Whether you’re exploring Right Size boxes on demand or want to better understand the impact of sustainable packaging solutions on things like Extended Producer Responsibility (EPR), our support team brings clarity. They’re here to troubleshoot, advise and assist at every step.

Why large businesses work with us

Ribble works best with businesses that have scale and are looking for a better way to do things. Most of our customers want to improve profitability. Others are focused on environmental impact. Some want to get ahead of legislation or make day-to-day operations smoother.

Whatever the driver, we help by:

  • Providing 100% recycled and recyclable corrugated packaging
  • Replacing one-size-fits-all boxes with fanfold corrugated board tailored to your product mix
  • Supporting automated systems that produce Right Size boxes on demand

The results are measurable: less waste, lower costs, and more control.

Ready to Rethink Packaging?

If you’re responsible for packaging, operations, logistics or sustainability, and you’re reviewing how to improve results, we’re always happy to talk packaging.

Find out more about our sustainable packaging solutions and Ribble could help you simplify your packaging process.

Contact us today through our website or call 0161 284 9000.

EPR Update: What’s Changing in 2025

Posted on by definitionconsulting

We’re now halfway through 2025, and Extended Producer Responsibility (EPR) is already reshaping how UK businesses manage, report, and pay for the packaging they place on the market.

Whether you’re a retailer, manufacturer, importer or wholesaler, chances are your 2024 data has already been submitted and your first set of EPR fees is either calculated or on the way. If you’re still catching up, now’s the time to act to stay compliant and to reduce your future costs.

A Quick Recap: What Is EPR?

Extended Producer Responsibility is a UK-wide scheme that shifts the cost of collecting and managing packaging waste away from local councils and onto the businesses that produce that packaging in the first place.

Under the rules, packaging producers must:

  • Collect and report data on the type and volume of packaging they handle
  • Pay fees based on how recyclable their packaging is and how much they put on the market
  • Take responsibility for packaging across its full lifecycle, from production to disposal

In practice, this means higher costs for businesses using hard-to-recycle materials and incentivises them to move towards more sustainable packaging solutions.

Where We Are Now in 2025

The EPR rollout began in 2023 with mandatory data collection. Although fees were initially expected to begin in 2024, they were deferred, giving businesses an extra year to prepare. In 2025:

  • Large organisations (those with turnover over £2 million and handling more than 50 tonnes of packaging) are now paying EPR fees based on their 2024 data
  • Small organisations (turnover over £1 million and handling more than 25 tonnes) had to submit their simplified data reports by 1 April 2025
  • Packaging fees are being issued through compliance schemes and the Environment Agency, and businesses should now budget for these ongoing annual costs

Want a breakdown of what those fees look like? Read the EPR fees and thresholds for 2025–2026 for cost bands, exemptions and materials.

Who Does EPR Apply To?

There’s still some confusion around eligibility. The EPR scheme doesn’t just affect packaging manufacturers, it applies to any business that:

  • Puts packaged goods on the UK market under its own brand
  • Imports packaged products for resale or internal use
  • Supplies empty packaging to third parties
  • Operates online retail or direct-to-consumer fulfilment

This includes wholesalers, supermarkets, e-commerce businesses, and contract packers. Even smaller businesses can be captured by the rules if their packaging volumes are high enough.

What Happens If You Don’t Comply?

Regulatory enforcement is active, and businesses that fail to submit data or pay their fees on time could face:

  • Fixed monetary penalties
  • Enforcement undertakings
  • Reputational damage
  • Long-term cost inefficiencies from unoptimised packaging

Moreover, failing to align with EPR expectations may limit your ability to work with larger customers who demand evidence of sustainability across the supply chain.

Reduce Costs with Smarter Packaging

Many businesses are now using EPR as a reason to reassess their packaging strategies. Beyond compliance, there’s an opportunity to reduce material use, improve recyclability and cut long-term costs.

At Ribble Packaging, we’ve seen strong demand for Right Size packaging solutions, using Fanfold material and automation to produce perfectly sized boxes with no void fill and minimal waste. It not only supports EPR goals but also cuts storage, transport and materials costs.

Switching to recyclable mono-materials and redesigning multi-component packaging can also have a significant impact on your future EPR fees.

What You Should Do Next

Check your reporting obligations — are you a small or large organisation under EPR?

  • Ensure your 2024 data has been submitted — and flag any inaccuracies before billing begins
  • Track your 2025 data now — this is what your 2026 fees will be based on
  • Review your packaging mix — can you remove complexity or reduce volume?
  • Talk to us — we can help assess your packaging footprint and explore cost saving options

Don’t Let EPR Catch You Off Guard

EPR is here to stay. And while the regulations can seem like just another set of boxes to tick, they’re a clear sign of where the packaging industry is heading — towards greater accountability, efficiency and sustainability.

At Ribble Packaging, we’re not just helping businesses meet compliance. We’re helping them future-proof their operations and packaging strategies for the long term.

Need guidance on your EPR obligations? Want to explore cost-saving packaging options? Contact our team, we’re happy to help.

Packaging That Works Across Industries: What Manufacturers Need and How Ribble Delivers

Posted on by definitionconsulting

When you think about packaging, it’s easy to picture a standard cardboard box. But for manufacturers and producers of goods, packaging is far more than that—it’s protection, presentation, efficiency, and even part of the customer experience. At Ribble Packaging, we understand that industry requirements vary. From furniture and kitchens, bedrooms, and bathrooms (KBB) to retail, print and beyond, we help businesses rethink packaging so it works smarter, not harder.

How Packaging Needs Change

Different sectors bring different challenges when it comes to packaging. In furniture manufacturing, for example, items are often large, heavy, and irregularly shaped. The goal isn’t just to protect during transit, but also to minimise warehouse space and reduce material usage without compromising safety. We support this with packaging solutions that create made-to-measure boxes, which reduce the risk of damage, lower shipping costs, and simplify packing for teams on the factory floor.

In contrast, the print industry has different priorities. Large runs of printed material—like brochures, point-of-sale assets or labels—need flat, stackable packaging that maintains product quality and avoids creasing. Volume consistency is common, but the need for speed and precision is high. Our solutions help streamline the packing process and reduce downtime, especially for companies working to tight campaign deadlines.

Retail and KBB (kitchens, bedrooms, and bathrooms) manufacturers also have different concerns. Retail packaging must not only protect the product but represent the brand well during the unboxing experience. KBB components often ship as part of flat packs or kits, requiring a flexible packaging system that can respond to multiple box sizes, fast. By integrating Right Size Packaging solutions into these environments, we help create consistency while adapting to demand.

The Right Size Packaging Advantage: Improving Efficiency Without Compromising Protection

Packaging inefficiencies can creep in easily, whether it’s using boxes that are too big, stockpiling packaging materials that aren’t used, or adding excessive filler to make products secure. For businesses producing hundreds or thousands of units, these small inefficiencies become costly over time.

Rather than shipping excess air or spending more on materials than necessary, manufacturers gain packaging that works for the product and the process. This is especially useful in production settings where space is limited or where packing needs change frequently.

Packaging That Supports Sustainability

Another key benefit is sustainability, as every industry is being urged to reduce waste and operate more responsibly, especially as the UK’s Extended Producer Responsibility (EPR) regulations are now in effect. Our Right Size Packaging solutions support this by cutting excess material and lowering your carbon footprint.

By replacing plastic void fill with recycled cardboard alternatives and reducing the number of returns due to packaging failure, manufacturers are seeing measurable environmental and cost benefits. This also positions your business to meet customer and regulatory expectations around packaging waste and recycling.

A Trusted Partner Across Production

So, whether you produce kitchens or catalogues, we understand the operational pressures that come with manufacturing and distribution. Our team advises and delivers the right packaging solution for your needs.

If you’re looking to create packaging that fits your product and your process, we’re ready to support you. Get in touch today on 0161 284 9000.

Is Cheap Packaging a False Economy?

Posted on by definitionconsulting

When it comes to packaging, many manufacturers are tempted to seek out the lowest cost option. On the surface, it seems a simple way to protect margins. But scratch beneath the surface and it quickly becomes clear: cheap packaging can end up costing your business far more in the long run.

 

The Hidden Costs of Cheap Packaging

First off, simply going too cheap on cardboard boxes risks them failing the basic function of protecting your product. It often leads to over-reliance on void filler and still leaves goods exposed to transit damage. Damaged products mean costly returns and can harm your reputation with customers.

When products are poorly packed, they also take up more space, resulting in higher transport costs. More deliveries, higher emissions and wasted space all combine to erode any initial savings made by selecting a lower-priced box.

Assembly time is another hidden cost. Complicated or flimsy packaging designs can slow down your operations significantly. Labour costs creep up when employees spend longer building, securing or replacing poor-quality boxes. This extra time drains resources that could otherwise be spent more productively.

If you are considering making a change, learn how to choose the right corrugated board for your packaging to make sure you select the right solution.

 

How to Reduce Packaging Costs

Reducing packaging costs doesn’t mean automatically choosing the cheapest materials. Instead, smart manufacturers look for ways to improve efficiency. High-quality, fit-for-purpose packaging can lower damage rates, speed up assembly and make logistics more cost-effective.

One simple but effective strategy is to design packaging that is easy and quick to assemble. Reducing assembly time can have a significant impact on labour costs, particularly for manufacturers handling large volumes. Well-designed packaging solutions improve speed and consistency within warehouses, helping your teams work smarter.

 

Right Size Packaging Works Out Cheaper

Right Size technology, such as Ribble’s Right Size solution, allows manufacturers to create packaging that perfectly fits each product. By eliminating excess space, you can drastically reduce material usage, cut down on void fill and make shipments more compact.

With less air being transported, shipping becomes more efficient, reducing both costs and environmental impact. Right Size also helps protect products more effectively during transit, meaning fewer damages and returns to manage.

 

How Rationalisation Can Save Money

Rationalising your packaging range can unlock further savings. By reviewing your existing packaging inventory and reducing the number of different box sizes and styles, you can simplify procurement, storage and operations.

Bulk ordering fewer types of packaging often leads to better unit costs. It also simplifies training for assembly teams and improves warehouse space utilisation. For manufacturers dealing with multiple product lines, rationalisation can bring welcome clarity and efficiency without sacrificing the quality or protection of the products.

 

Packaging That Supports Your Business Growth

Choosing the right packaging partner can make a significant difference to your bottom line. At Ribble Packaging, we help businesses like you reduce packaging costs the smart way, without compromising on product protection, efficiency or sustainability.

Explore how our tailored solutions, including Right Size technology, can help your business. Get in touch today on 0161 284 9000.

Extended Producer Responsibility (EPR): What It Means for Your Business and How to Prepare

Posted on by definitionconsulting

With the UK’s Extended Producer Responsibility (EPR) regulations now in effect, businesses involved in packaging must take immediate action to avoid penalties. Yet, many are still unaware of the financial implications and their obligations under these new rules.

But what exactly is EPR, and why should it matter to your business?

EPR is a regulatory initiative designed to make producers accountable for the entire lifecycle of their packaging. Previously, the burden of these costs was entirely or in part covered by local government. The aim is to improve recycling rates, reduce landfill waste and encourage more sustainable packaging solutions.

Under EPR, businesses must report the amount and type of packaging they place on the UK market and pay fees based on these figures. The fees collected will help fund recycling programs and waste management improvements.

While this move aligns with the UK’s sustainability goals, it also creates new responsibilities for businesses of all sizes. Those failing to comply face fines and potential restrictions on their ability to trade.

The EPR packaging fees associated with the new laws were initially set for 2024 but were deferred for a year, meaning companies did not have to pay any fees in 2024. However, they will now be required to pay the related fees in 2025, based on 2024 data.

Does EPR Apply to Your Business?

A common misconception is that only manufacturers are affected by Extended Producer Responsibility. That’s not true, as the regulations will apply to a wide range of businesses, including importers, wholesalers and retailers. If your business supplies packaged goods in any capacity, you are considered a “producer” and must comply with EPR rules.

Even smaller businesses that import packaged products from overseas are not exempt. Companies must assess their packaging footprint now to determine their obligations and avoid any compliance risks down the line.

If you are a large organisation, the data you collect and report in 2024 will be used to calculate your recycling obligation and any waste management fees you must pay in 2025. Small producers must collect their 2024 data and report it by 1 April 2025.

Find out if you’re a small or large organisation and what this means.

How to Prepare for EPR

The first step is to register with the Environment Agency or the equivalent regulatory body in Scotland, Wales, or Northern Ireland. Once registered, businesses must track and report their annual packaging data, detailing the materials used and the volume placed on the market.

Producers will then be required to pay fees based on their packaging output. Non-compliance could result in financial penalties, or worse, a ban on selling non-compliant packaged products. With the first reporting deadline for 2024 data set for 1 April 2025, businesses must ensure they have the right processes in place to capture and submit accurate data.

Changing to Sustainable Packaging

The introduction of Extended Producer Responsibility is pushing businesses to rethink their packaging strategies. Many companies are already moving towards more sustainable packaging materials, but with the financial costs of EPR now attached to packaging waste, businesses will need to accelerate their efforts.

Many of our clients are turning to Right Size solutions, which combines 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, reducing the need for void fillers and excess packaging.

At Ribble Packaging, we specialise in helping businesses optimise their packaging solutions. Whether you need guidance on EPR compliance or want to explore more sustainable packaging options, our team is here to support you through the transition.

Get the Right Support

With the first reporting deadline approaching, businesses must take EPR seriously. Understanding your obligations, tracking your packaging data and taking steps to reduce waste will not only keep your business compliant but also contribute to a more sustainable future.

If you’re unsure where to start, speak to one of our experts at Ribble Packaging today to find out how we can support you.

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

Your Guide to Optimised Cardboard Box Designs

Posted on by definitionconsulting

Optimised packaging plays a significant role in reducing waste, lowering costs, and improving supply chain efficiency. With updated EPR regulations fast approaching, businesses are actively refining their packaging to enhance product protection, minimise excess materials, and lower shipping expenses.

At Ribble Packaging, with over 80 years of packaging expertise, we’re here to guide you through key design considerations, optimisation strategies, and the many benefits of improving cardboard box designs.

Choosing the Right Cardboard Box Design

The first step in optimising your packaging is choosing the right box size and fit for your product. Oversized boxes not only increase material use but also lead to higher shipping costs. A well-fitted box ensures secure transit and reduces the need for additional void fill.

Box Style

Different products require different box styles. Some common options include:

  • 0201 Regular Slotted Case (RSC): Cost-effective and widely used, suitable for various industries
  • Die-Cut Boxes: Custom-designed to fit specific products, reducing movement and improving presentation
  • Crash-Lock Bases: Quick to assemble, enhancing packing speed and reducing labour costs

Product Considerations

When choosing your box design, consider factors like product type, shipping method, and whether you’re shipping to customers or B2B. For example, shipping directly to end customers may require more focus on presentation. Additionally, the nature of your product, whether heavy, fragile or requiring special storage conditions, will influence the structural integrity and material choice for your box.

Board Grade

To understand box strength, you must first understand the available board grades. The strength and sustainability of a box depend on its board grade:

  • Single-wall: Suitable for lightweight products and cost-effective solutions
  • Double-wall: Offers additional strength, ideal for heavier items

Get a full breakdown of board grades, including details on the different types of corrugated boards and how flutes affect strength and functionality.

How to Optimise Your Packaging

Board Material

Selecting the right board grade allows you to balance strength with cost-effectiveness. Lighter materials reduce expenses while still maintaining product protection. A popular choice is fanfold corrugated board.

Getting Your Box Adjusted with 3D Technology

Optimising your packaging design can also involve the use of 3D scanning technology. This allows you to scan the product and design packaging with precise dimensions, eliminating unnecessary waste. Through 3D technology, you can create custom-sized boxes on demand, reducing excess material use and lowering shipping expenses by ensuring a perfect fit every time.

These designs can also be integrated with Panotec Automation, to create custom boxes on demand, streamlining the process and reducing manual labour. By setting the box dimensions, you can instantly produce custom boxes without waiting for long lead times, improving efficiency across the supply chain.

 

Why Change My Current Box Designs?

Making the shift to optimised packaging might feel like a big step, but the benefits far outweigh the effort. If you’re still using outdated box designs, you’re likely overpaying for material costs, wasting space, and even damaging your products during transit. Optimising your packaging doesn’t just save money; it also contributes to a greener and more sustainable supply chain.

 

How Ribble’s Design and Estimating Team Can Help

Many businesses we’ve worked with have already improved their packaging process by reviewing their board grades and product styles, as well as using Panotec’s cutting-edge 3D imaging technology.

The results speak for themselves:

  • Up to 30% reduction in overall packaging costs
  • 25% improvement in vehicle utilisation
  • More efficient use of warehouse space
  • Environmentally sustainable packaging process

Whether you need better product protection, cost savings or sustainable packaging solutions, Ribble provides expert guidance to ensure your packaging meets its intended purpose.

Talk to us about your packaging design at Ribble Packaging or call 0161 284 9000.

How to Choose the Right Corrugated Board

Posted on by definitionconsulting

Which board grade is right for you?

Not all corrugated packaging is the same and picking the right type can make all the difference in protecting your products and reducing costs. With so many board grades and constructions available, each designed for a specific purpose, selecting the right solution can quickly become confusing. We wanted to make it easier for you to understand the choices available and what is best for your individual needs.

Understanding Corrugated Material

Corrugated material is a versatile and durable packaging solution made by combining layers of paperboard. It provides excellent protection during transit and storage while offering flexibility in design and presentation. The process begins with flat sheets of paper, which are then processed through a corrugating machine to create ridges, known as flutes, between layers. These flutes add strength and cushioning to the board, ensuring it can handle various weights and impacts.

Construction and Types of Corrugated Board

1. Single Wall Corrugated Board

Single wall is the most common type of corrugated board, consisting of three layers: a liner (outer layers), a medium (fluted layer), and a liner again. It is ideal for lighter packaging needs and provides good protection for fragile goods. For example, a single wall board typically has a strength rating of B or C flutes, which provide a good balance between durability and flexibility.

2. Double Wall Corrugated Board

Double wall board consists of two fluted layers sandwiched between two outer liners. This construction is suited for heavier and more fragile items, offering enhanced protection and durability. Double wall is often used for industrial goods, electronics and products that require extra impact resistance.

Flutes Explained

Flutes are the ridges formed between the layers of corrugated material and come in different sizes and shapes to serve various packaging needs.

  • A Flute: The largest flute, offering excellent strength and cushioning. Ideal for heavy-duty industrial applications.
  • B Flute: Amongst the most commonly used types of cardboard used for packaging applications. Exceptionally versatile used in both die cutting and regular case-making processes. It gives good all-round performance in all types of packaging.
  • C Flute: A balanced option that provides good cushioning and stiffness, suitable for a wide range of uses.
  • E Flute: A finer flute, known for a smooth finish and better dimensional stability. Often used for lighter consumer goods.
  • BD Flute: Around 4.3mm to 4.8mm thick, BD flute combines B and D flutes into a double walled material.
  • BC Flute: This double wall material combines both B and C flutes together. This gives a good all round performance, making it common for producing shipping boxes that offer a higher level of transit protection.

 

Choosing the Right Corrugated Solution

Selecting the appropriate board grade, construction and flute type helps your packaging meet both your protective needs and environmental standards. Corrugated boards provide not only durability but also sustainability, as according to FEFCO, corrugated board is one of the most recycled materials in Europe, with an impressive 89% recycling rate. This ensures that the majority of corrugated products are recovered and reused, contributing significantly to a circular economy, helping businesses reduce waste, lower carbon footprint, and meet increasing demands for eco-conscious operations.

Additionally, many boards are biodegradable, breaking down naturally without harming the environment, a win-win for businesses and the planet.

Ribble Packaging

At Ribble Packaging, we offer bespoke cardboard packaging solutions for businesses of any size. With our central UK location, we provide efficient national delivery, ensuring your packaging needs are met promptly. Our process includes the use of an onsite corrugator with a state-of-the-art Fanfold down-stacking facility. Supported by our onsite conversion plant, we also offer case-making and die-cutting capabilities to create the perfect packaging solution for your business.

Contact us or call 0161 284 9000.

Packaging Trends 2025

Posted on by definitionconsulting

It’s guaranteed that we will see industries change their packaging in 2025 to avoid additional costs and remain profitable. With new regulations, economic pressures, and sustainability goals shaping this movement, let us discuss what is driving these upcoming changes and what businesses are doing to stay resilient and environmentally responsible.

What will affect trends

Extended Producer Responsibility (EPR)

EPR mandates that producers bear the financial and operational responsibility for the disposal of packaging waste. In the UK, EPR regulations are set to take effect from January 2025, introducing revised recycling targets through to 2030. Cardboard is naturally recyclable and aligns well with EPR requirements, making it a more compliant and cost-effective choice compared to plastic. If you are a manufacturer, here’s what you need to know about EPR.

Economic Environment

The UK’s economy is experiencing notable changes, with inflation forecasted to stay above the Bank of England’s target until late 2026, this is driven by rising business costs and global trade disruptions. Adding to these challenges National Insurance contributions will rise from 13.8% to 15% and the National Living Wage for those aged 21 and over will increase by 6.7%. The annual wage growth is also expected to rise to 3.8% in 2025. All these factors raise operational costs, prompting companies to seek efficiencies in their packaging processes.

Sustainability Targets

Consumers and governments are intensifying their focus on environmental sustainability. Large organisations will face looming deadlines to meet their sustainability goals by 2025, driving a significant shift towards eco-friendly packaging solutions. Companies are turning to materials like cardboard, which are biodegradable, renewable and widely recyclable.

Key Packaging Trends for 2025

  1. Automation to Address Labour Costs

With rising labour expenses, automation in packaging offers a viable solution. Implementing automated systems can improve production speed, reduce errors, and achieve long-term cost savings. Panotec is one of the leading providers of automated packaging solutions, helping manufacturers produce custom-sized boxes on demand.

With various sizes depending on your production requirements, businesses can meet growing demand while maintaining cost control and consistency.

  1. Packaging Optimisation

Packaging optimisation focuses on reducing material waste and improving design functionality. This can be highlighted in Ribble’s Right Size packaging, which 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.

  1. Transition to Cardboard and Paper Packaging

With EPR regulations increasing the cost of plastic waste management, the shift to cardboard and paper-based packaging is rising. Cardboard packaging aligns with these requirements as it is renewable, recyclable and widely accepted by both industrial and municipal recycling systems.

The Future of Packaging with Ribble

Ribble’s expertise in corrugated cardboard solutions provides businesses with options that meet regulatory demands while supporting sustainability goals. From recyclable shipping boxes to bespoke cardboard designs, businesses can replace plastic with eco-friendly alternatives that resonate with consumers’ preferences for greener products.

Get ahead of the curve and see how Ribble Packaging can transform your approach to packaging in 2025. Contact our team today on 0161 284 9000 or through our website to learn more about our innovative, sustainable cardboard packaging solutions.

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