Tag: automation

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.

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.

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.

Your Questions Answered: Insights on Packaging Automation

Posted on by definitionconsulting

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

 

 1. In what ways can packaging be automated?

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

 

2. What are the key benefits?

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

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

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

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

 

3. Are there opportunities to scale up the solution?

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

 

4. How does automation enhance sustainability?

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

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

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

 

5. How has the reception been so far?

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

 

6. How will independent retailers benefit?

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

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

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

 

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

Solving the Furniture Industry’s Damaged Goods Dilemma

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.

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