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.

How to take back control of your packaging supply in 2021

Deemed the new ‘beige gold’, cardboard supply is still very much in high demand as a result of the ongoing coronavirus pandemic and the dramatic increase in online shopping has led to this over the past 12 months.

According to The IMRG Capgemini Online Retail Index, the UK’s eCommerce sector achieved the highest online sales growth in 13 years. Total online retail sales growth was up 36% in 2020, so it’s not surprising the devastating effects this has had on businesses nationwide.

Struggling to cope with cardboard material supply, many online retailers have experienced a delay in their deliveries, which in turn has been impactful on their customer satisfaction. Even the big retailers, Asda, Lidl and the Co-op started to feel the pinch early on last year, as many consumers were asking why their egg packaging was replaced with plastic packaging. This was an early warning of what was to come for the world of packaging…

Before the pandemic, businesses were relatively responsible when it came to recycling. Packaging would be quickly returned into the recycling system, but now the industry tackles the problem of relying on individuals to recycle properly.

“What we’ve found is people tend to store product boxes in their garages or simply in their homes without realising the detrimental effects this is having on cardboard supply,” says Stephen Rector, Managing Director at Ribble Packaging.

Less recyclable cardboard is being returned into the system and paper manufacturers are struggling to create the supply to meet demand. Paper has become scarce, and some corrugated manufacturers are having to ration their supply and let customers down.

So how can you future-proof your packaging supply chain in a volatile market?

By implementing a Right Size packaging solution.

Fit-to-product boxes can help by considerably cutting the amount of cardboard you use. By only using the right size box, it means you only have to purchase one type of packaging material such as Fanfold, removing the need to order multiple styles and sizes.

This flexible on-demand right size packaging solution is guaranteed to save you up to 25% in packaging costs and is a much more sustainable solution, as it removes the need to purchase additional void fillers; a win, win.

To find out more about Ribble Right Size, please click here or get in touch and we’d be happy to discuss your options.

 

4 Reasons Why Corrugated Board Is The Answer To The Plastic Problem

It is estimated that eight million tonnes of plastic waste ends up in the oceans every single year. With marine life threatened as well as seabirds, with their inadvertent consumption of plastic, it is no surprise that there has been a sharp increase in concern lately. More and more people are becoming worried about the threat of plastic and the environmental devastation that plastic is causing.

With demand for the reduction in plastic growing, consumers are desperate for businesses to come up with better ways to package products. However, what is the solution when almost all packaging seems to use plastic in some form? Well, surprisingly, corrugated board may be the answer to the plastic problem that the world is facing. Here are just four of the reasons why.

Four reasons why corrugated board is the answer to the plastic problem

 

  • Food packaging

 

Plastic is prevalent in supermarkets where lots of food are wrapped or stored in plastic containers for customer convenience. When it comes to fresh food, plastic can help to provide a stable base for the food to prevent damage; it can also help to make it easier when shipping and transporting goods. However, corrugated cardboard can offer the same benefits without the burden of adding more plastic to the environment.

Corrugated board is stable and provides a secure base for food and well as being easy to carry, transport and ship. Lots of fruit suppliers already use corrugated card for this reason. However, corrugated card can be used for a range of different food items. Especially as corrugated board can help to keep moisture away from products, which can increase their lifespan and ensure foods can withstand a long shipping journey.

As corrugated board is incredibly versatile with different thicknesses, shapes and sizes, it makes it incredibly versatile for a range of food items. This means customers can avoid unnecessary plastic when loading up their trolleys.

 

  • Custom creations

 

Plastic is often chosen for packaging as it can be moulded into a range of shapes to suit a range of products. However, corrugated board is just as versatile and customisable. The thickness of corrugated cardboard can be altered to suit different products while the fact it can be cut to any size and create a range of shapes mean it is easy to create a bespoke packaging container using cardboard alone.

What’s more, the corrugated board can receive a range of treatment and coating to help bolster the strength and versatility of the packaging. For safety, corrugated cardboard can be coated with a waterproof material as well as flame resistant material to make it an ideal packaging choice for a range of different industries.

Cardboard can then be printed using digital and screen printing to create a vibrant design for your packaging. This can help you to increase visibility for your brand, become a powerful marketing method and ensure your products and packaging stand out from the crowd. While plastic can also be customised, the fact that you can print directly onto corrugated board means it is cheaper, quicker and more convenient to produce.

 

  • Sustainability

 

Corrugated board can be made from 100% recycled material. Furthermore, it can be completely recycled after use. As well as being recycled, corrugated board is strong enough to be reused many times. In most cases, corrugated cardboard can be folded down flat for storage and then be used again when it is needed.

With sustainability at the forefront of people’s minds, it has never been so important to promote greener materials, products and packaging. With more and more people wanting to veer away from non-degradable plastic, the corrugated board provides the perfect sustainable packaging alternative to plastic.

By printing messages directly onto the cardboard, you can make it clear to customers how sustainable your packaging is and how they can dispose of your packaging after use.

 

  • Cost-effective

 

Corrugated board can be a cost-effective packaging solution for many businesses. Firstly, corrugated cardboard is relatively cheap to produce and budget-friendly to purchase. Secondly, it is lightweight for packaging which may help to lower the total weight of products when shipping. This means that you can achieve savings in shipping costs, whether you use a third-party supplier or by saving money on the fuel used to transport goods.

Furthermore, corrugated cardboard can be shaped to fit custom product sizes, which means you can save space when shipping, helping you to send more items for the same cost which will help your bottom line.

The Box Manufacturing Process Explained

The humble cardboard box is one of the most used packaging materials. It is a core product in packaging manufacturing. It not only fills the shelves, but it can be seen all throughout the supply chain too. When looking at a cardboard box, typically printed and branded with inviting colours and wording, it is hard to imagine it started life as a tree. We discuss the box manufacturing process step by step.

As consumers, we often forget to consider how items came to be, but we think the packaging should be celebrated. So, how does a tree finally become a box?

The steps of box manufacturing

1.     The tree

While we ideally look for recycled cardboard for box production, at one point, a cardboard box started life as a tree. Typically, the trees used for box manufacturing are softwood trees such as pine and fir tree. The reason they are chosen is that they have long fibres which can help to create a smooth finish for the cardboard as well as creating tension which increases the strength.

Many manufacturers will choose wood from sustainable and managed woodland; this means that any trees that are felled are replaced to help maintain the ecosystem of the forest. The paper and cardboard created will have a different colouring depending on the tree used. For example, silver birch trees will produce a dark colour, while a spruce will create a light brown colour.

2.     The pulp

From felling the tree, wood chips are made. These wood chips are then broken down into pulp. This can be done through grinding the wood against a stone or chemically cooking the wood chips. With this, you can add chemicals such as sodium sulphate to increase the strength of the pulp. For most cardboard, the pulp is left as the same colour. However, it can also be bleached to create a white appearance.

3.     Corrugation

Once the pulp has been dried, you can then start to create cardboard. For corrugated cardboard, it requires two pieces of paper or card called liners and a portion of fluted cardboard, which sits in between the liners. To fluting helps to give the cardboard further strength and a higher level of protection against damage.

Rolls of the paper made from the dried pulp are fed through a corrugated roller, which flutes or ruffles the paper. Depending on the quality of the box being made will depend on the level of fluting required. As increasing the fluting leads to higher use of material and therefore increased strength, this is used for high-quality boxes. For cheaper boxes, less fluting can be used which can help to create space-saving, a reduced amount of material used and can lower the carbon emissions.

The corrugation machine uses hot steam to create the flutes. At the same time glue is rolled down each side of the flute, so that is sticks to the liners. Once corrugated cardboard is formed, it is then trimmed to provide straight edges.

4.     Cutting

Now that you have complete corrugated cardboard, it is time to cut the card to size, depending on the box requirements. There is a comprehensive guide, and many of the machines are programmed to cut the cardboard to scale automatically depending on production demand. Once the basic outline has been cut, the card is then sent to a trimmer.

The trimmer is designed to deal with intricate aspects that the cutting machine cannot handle. A trimmer can add handles to boxes and cut flaps that are needed to construct the box. The trimmer also scores the cardboard, making it easier to fold when the box is ready for assembly.

5.     Assembly

Assembly will depend on the requirements of the box. The use of flaps and slots may be best for business who want to construct their boxes on demand. As well as these, boxes built with tape are often efficient to be constructed as and when they are required. Usually, for more robust boxes, glue and stitching are used to fold sections together and keep the box secure.

Specific innovative machinery can construct boxes for you on demand. For example, Box on Demand is an on-demand box making machine. It creates the perfect size box depending on your needs to reduce waste and ensure the best fit. The box is constructed for you which can significantly reduce packing production time.

After assembly, offcuts can be recycled to continue in the chain of box making. After the boxes have been branded, printed and utilised, they can be recycled and create a continuous cycle of recycled box manufacturing.

 

Why Is Cardboard The Best Packaging Material?

Is cardboard the best packaging material? Its popularity is evident but why?

For businesses of any size, you need to be sure that your products are well-protected. Not only do you need to make sure that items have great packaging to prevent damage, but there are also a wealth of other considerations to think about. Aspects of packaging that you may consider could include its environmentally-friendly credentials, aesthetic qualities, practicality and ease of transportation.

Here we look at some of the many reasons that cardboard consistently comes through as an excellent material for packaging

Five reasons why cardboard is the best packaging material

1.     Versatility

Cardboard can be creatively adapted to suit a range of products in varying shapes and sizes. Utilising advanced designs, cardboard packaging can have multi-uses or create forms never thought possible.

In some cases, brands have created their cardboard packaging to offer a further use after packaging. This extends the life of the product and shows the brand’s commitment to less waste. For example, clothes brands can use cardboard packaging which can be transformed into clothes hangers, giving consumers a further use out of their packaging.

With its versatility, you have to option to package many products using the same material. For example, Ribble offer on-demand box making technology, Box on Demand, so you can have the right box for your product and save on wastage.

2.     Ideal branding

While plain cardboard can be an effective packaging design in itself, cardboard can easily be transformed through colour, shape and branding. Cardboard is easy to print on or embossed to create genuinely personal packaging.

Using colours and logos, cardboard can quickly be transformed from dull packaging into vibrant and exciting protection that makes your brand easy to identify. Consider cardboard as a blank canvas, upon which you can convert with your wording and imagery to make your products fly off the shelves.

3.     Recyclable

Another considerable advantage of cardboard packaging is the fact that it is recyclable. For consumers, this brings many benefits as it is easy to dispose of and does not need special treatment to get rid of it. Most councils will pick up cardboard through their recycling collection programme, while there are many places to recycle cardboard across the UK.

What’s more, cardboard can be made of recycled material too. At Ribble, all of our boxes are made from 100% fully recycled material as well as being recyclable at the end of life also.

4.     Cut transportation costs (and the carbon footprint)

As cardboard is lightweight, it makes means the packaging does not add too much to the weight of the product overall. With lighter packaging, it makes products easier to transport and more cost-effective as you save on fuel when you save on weight. By saving on fuel, your transportation costs can be significantly reduced. Not only do you see cost-savings, but you can also reduce your carbon footprint by using less fuel.

In terms of transportation, cardboard is also very durable making it the best packaging material for business. It helps to prevent moisture from infiltrating the product; this is an essential factor for products that need to withstand long transportation times, as well as protecting food products.

5.     Cost-effective

Compared to many other packaging products, cardboard is an extremely viable option for businesses of any size. Cardboard is considered particularly cheap compared to more expensive packaging solutions such as plastic. If assessing solutions such as corrugated cardboard, then these are highly affordable as they require less material than normal cardboard, yet still give robust protection and are lightweight too.

By ordering cardboard in bulk, you can often save considerably on your packaging costs. Also, as cardboard packaging is usually delivered flatpack, you can order in bulk but still have the room to store it, so it is there when you need it, but does not take up an excessive amount of space.

Choosing cardboard for your packaging solution

If you are trying to find the perfect material for your packaging needs, then speak to the experts at Ribble. Ribble offers a wealth of cardboard packaging solutions that are recyclable and versatile. From standard boxes to bespoke packing systems, Ribble can help to ensure you have an innovative packaging solution that meets all your needs. What’s more, Ribble work with all manner of businesses, offering competitive solutions for small and large companies.

Find out more by getting in touch.

Welcome to Ribble Packaging!

Welcome to Ribble Packaging, a leading UK packaging company that has been delivering an outstanding service to clients for over 75 years.

Our expert team help businesses from all kinds of sectors with their cardboard and packaging requirements. Our central UK location means that we offer efficient national delivery.

UK Cardboard Packaging Manufacturers

Originally established in 1938, Ribble Packaging are always looking to move forward and innovate. In 2013 we invested £3.5m in a new, fully automated manufacturing and stacking system, that would allow our service to improve, and in 2016 we opened a state of the art Centre of Excellence for Ribble Restore.

Ribble Restore removes the hassle returns management for businesses allowing them to make significant savings, build an advantage over their competitors and enhance customer and supplier relationships. Ribble Restore allows businesses to recover valuable stock and repack it in pristine boxes, ready for reuse.

Ribble Automate is an innovative packaging service from Ribble Packaging that allows businesses to streamline their packaging process, thereby reducing overall costs. We can provide your business with boxes that are the perfect size, reducing waste and saving you up to 25% on annual corrugated spend. Automate reduces product returns as items are well protected and arrive intact.

If your business needs high-quality cardboard boxes fast, then our Ribble Packaging service can help. Whatever the scale of the order or the size of the boxes, Ribble Packaging provide a fast cardboard packaging service to clients of all kinds. We approach each project with the same attention to detail and excellent customer service.

Contact Ribble Packaging for Cardboard Packaging

For more information on our UK cardboard packaging services, please get in touch with Ribble Packaging today. Contact us online to discuss your business’ requirements or call our team directly on 0161 622 2302. Our friendly team are on hand to help you find the service that best suits you.

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