5 Easy to Implement Manufacturing Product Packaging Solutions

When you’re focusing on the quality of the product, you need simple product packaging solutions that take the stress away and allows you to concentrate on the central aspect; your product.

1. Flat pack solutions

Flat pack furniture came about when a Swedish draughtsman had to unscrew the legs off a table to fit it into his car. The experience made him wonder about developing a system where furniture could be manufactured in a kit form. The Swedish legacy lives in one of the largest flatpack furniture retailers that have stores across the globe. While the concept of flat pack relates to the design and manufacture of the furniture, it has generated an entirely new process in packaging. Flat pack furniture comes unassembled. It is therefore packaged with sometimes hundreds of small bits and pieces as part of the greater package.

This has led to the necessity for product specific flat pack packaging, where the goods are packaged as tightly and with as much space economy as possible. The consequence is that people can fit an entire bedroom’s furniture into the back of their car. The need to design boxes that fit into boxes to take advantage of all interior space came with the advent of flat packed products, and innovative furniture packaging has led to the development of newer solutions. These solutions, however, have not left the flat pack in the corridors of obsolescence. It could be argued that the special economics of flat pack packaging is the grandparent of modern compact packaging solutions.

When retailing larger products particularly, furniture flatpack makes storage and sales implementation a dream.

2. Automated solutions

Automated packaging comes in all different shapes and sizes and can be varied depending on your requirements. This type of packaging can be used for both perishable and non-perishable products, but is also useful, with small furniture items. Flatpack designs have now become so flexible that they form part of automated packaging systems. While flat packing is an innovative packaging method, it marries well with automation to offer an easy production line solution in manufacturing. While automated packaging saves time, it is the precursor to what has become the packaging method of preference in large warehousing operations – on demand packaging.

In situations where a business warehouses its stock, automating the packaging process makes sense. There are times when combining one other or all of the methods mentioned in this post can form part of the automation process and automation makes sense, particularly when running a twenty-four-hour operation.

When a product line can be assembled in a uniform size and shape, automated packaging usually makes sense. It must be noted however that automated and on-demand packaging are two different processes.

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3. On-demand product packaging solutions

On-demand packaging is probably one of the most versatile and innovative product packaging solutions developed yet. On-demand machines package, according to the size and shape of the products placed on the device. In other words, every product can be different, and the machine will wrap the item according to its weight and dimensions. Apart from saving space in transit, this type of packaging saves time and labour costs. The on-demand packaging also means that items can be packaged when and where the warehouse wants it to happen.

On-demand machines will build the custom packaging for a particular product in real time, saving storage space, packaging materials and make reverse logistics a much easier process – the perfect packing solution.

4. Hexacomb packaging

Hexacomb packaging is extremely lightweight cardboard packaging constructed with a typical honeycomb design. The honeycomb design provides immense strength while reducing the amount of weight that conventional strips of packaging would to the end product. When products such as furniture are heavy, this product has done its duty to reduce even more potential weight to the fully packaged product. This packaging can also be cut and shaped to snugly fit into vulnerable furniture parts keeping them safe in transit.

This kind of packaging usually forms part of a greater product packaging solutions strategy and demonstrates a solution for otherwise difficult items to ship.

5. Protective packaging

Protective product packaging solutions come in a variety of shapes and forms. It is most commonly identified as packaging that is designed to fit over sharp corners of furniture such as on tables and cabinets. Often surface protection is also provided for polished wooden tables. In the past, polystyrene was consistently used for its protective packaging properties, however, as environmental factors have become a consideration, it is now more common to see these packaging products made with recyclable corrugated cardboard.

These pieces of additional protective packaging not only serve as protection for the item to which they are attached but also as a safety precaution to prevent damage to vulnerable items that are transported with them.


Want your packaging simplified?

If you want to make packaging your products easier with, then talk to the leading product packaging experts in the UK. Our friendly advisors will help you to keep costs and time down with the best sustainable packaging solution for your needs.

Top Ten Most Innovative Cardboard Packaging Designs

Cardboard box design is something we take for granted. It appears every day in our lives, and we don’t think twice about what has gone into the design of the innovative cardboard packaging we use, whether it’s a milk carton, a book delivery through the door, or a box that we use to move to a new house. It’s simply always there. Imagine, however, if we woke up one day and cardboard packaging was banned!

There have been several innovations in cardboard packaging, since 1821, the year that cardboard was developed as a packaging product. The first cardboard packaging as we know it today arrived in 1890 and was designed by Robert Gair a Scotsman whose discovery was made by accident.

But have you stopped to think how over the decades these early innovations and developments have led to the versatile use of innovative cardboard packaging design as we know it today?

  1. Cardboard Tubing

Who said cardboard boxes had to be square? Over time the human tendency to “think outside of the box” and innovate according to both functional need and creative growth has been fed by the versatility of the cardboard box. When cardboard tubing first became an everyday product, many problems were resolved. The lowly toilet roll, something we all use every day could now be packaged and rolled without any further packaging issues, Architectural drawings, posters and prints are kept safe both for long-term storage and transportation. Cardboard tubes are frequently used to package high-end wine and spirit products, to name but a few.

  1. The Classic Flatpack

product packaging box

Most modern boxes with six sides are now designed to be flat packed. This is exceptionally handy for mass production so that once the box has been used, it can be flattened again and then stored for reuse at a later stage. Good examples of flatpack boxes that we see and use every day are boxes made for house moves, packaging for posting, and other bulk product packaging boxes.

  1. Milk And Juice Cartons

Intelligent and innovative cardboard packaging design for the function hasn’t only been about how boxes flatten down and can be rebuilt. Using cardboard for food packaging continues to surprise anew. Milk cartons are coated with a waterproof coating, and the type of waterproof layer will vary depending on the laws of the country in which it is manufactured, but had it not been for cardboard, the milk and juice cartons that are so familiar today would not exist.

  1. The Pizza Box

The humble pizza box, shallow, wide and long, depending on the size of the pizza has become a favourite, and its design and use has expanded to other food ideas such as the munchie box specials offered by takeaways, but also enabled designers to work around awkward products such as clocks. The pizza box is definitely an innovation with the feeling of hunger and optimism that it provides the minute you see one.

  1. The Wine Carrier

Ever been shopping for a party and discovered the round shape of the bottle make them difficult to carry, even in a plastic carrier bag? The bottle carrier has rescued many a bottle from an untimely demise. These cardboard carriers can usually transport anything from four to six bottles with a convenient carry handle and are remarkably robust and secure. Usually, these can be flat packed for storage and reuse.

  1. The Fold Open Cardboard Package

If you have ordered a book from one of the large online suppliers, you’ll be familiar with this packaging, and it’s relatively new on the scene. All you need to do is pull a tab or use a little – not a lot of force to pull it open, and it stretches out to a flat piece of cardboard with your product lying slightly off centre, having been delivered safely and securely.

  1. The Archive Box

Storage boxes, come by many names and should not be confused with the flatpack, product packaging or moving box. These come with handles cut out of the side of the box and a lid, which enables continued use of the box and access to the box long before it needs to be discarded. These boxes can be utilised for decades before they require replacement. Sometimes referred to as file boxes, they are an investment that many businesses make and are often used as evidence storage by law enforcement across the world.

  1. Egg Boxes

cardboard egg box design

Eggs are probably the one item in the supermarket trolley that are the easiest to break and yet the design of the egg box is one that is light, practical and offers safety and security to the contents like few other packaging ideas. Cardboard is the best material because not only is it functional in design, but it also can absorb a substantial amount of movement and compression before the contents become damaged.

  1. The Tissue Box

The tissue box made it into this list because it has to be open to serve its purpose. This little space saver comes in all shapes and sizes, can be kept anywhere, be it the home, the car, the office and even mini boxes in the handbag. The beauty of it is that no matter how few tissues are in it, it continues to serve its purpose until the last one is gone. Without the tissue box, we’d have tissues and napkins everywhere, making a huge mess of the surroundings.

  1. The Pet Carrier

Thinks pets, you may think cats and dogs, but the widespread and bespoke use of cardboard carriers for animals can be seen at veterinary clinics, airports, rescue centres and elsewhere. They are to carry many animals from reptiles, to kittens, hamsters to hedgehogs. The cardboard packaging is robust, yet safe to the touch this design is perfect for scared or aggressive animals, and they come in larger sizes too that can accommodate sedated dogs too.


Innovative cardboard packaging solutions from Ribble Packaging

Whether you are at home or out in town, have a look around you, and you’ll see a diversity of packaging that we use every day and simply take for granted. Just imagine if we woke up one day and none of it was there!

If you need an innovative cardboard packaging solution, then talk to the experts at Ribble Pack who may be able to meet your design and product needs for your packaging to become the next most innovation cardboard solution. Whatever your packaging needs, the Ribble experts are here to help.

7 Specialist Packaging Solution Tips For Manufacturers

Whether your business is business to business or business to consumer, your packaging matters. How you package your products differentiates you from your competitors. While it often comes last on the list of priorities to businesses, your packaging is often the first tangible side of your business that your customers will see and feel. How you package your products can show the level of quality and speaks volumes on how you value protection and the goods that are contained inside. In this post, we share 7 specialist packaging solution tips for manufacturers to help you make the most more of your packaging.

The way you ship items says a lot about your business. Your business might be considered illogical, even stupid if the box isn’t big enough or is incredibly oversized that it is incomprehensible. The packaging you use ultimately reflects your brand and your company’s core values, whether you are eco-conscious or passionate about customer care.

Your value for the environment is one of the ways customers will judge your business. Consumers are becoming more environmentally aware; looking to buy from firms that care about recycling and ensure their products and packaging is sustainable. Customers also look at reducing their use of plastic and waste, so while you may think your products are most important, how you encase and deliver them has an impact too.

Packaging To Cut Costs

On the list of business improvements, packaging often has the lowest priority, but many companies are overlooking one of the largest cost-saving opportunities. By examining and altering your packaging, you can dramatically cut costs.

You can reduce costs through many aspects of packaging. Obviously, the key element is the right packaging will protect the goods inside which will reduce returns, damage and breakages. For mirror manufacturers, for example, the correct packaging with a specialist packaging solution is essential to ensure the mirror is delivered in good condition surviving the wear and tear of travel as well as surviving all manner of environmental conditions it is subjected to. The single most cost-saving solution regarding packaging is to have the right-sized packaging for your product.
By having the right-sized packaging you can cut costs through wasted space, the amount of protective materials and filler you use, the time spent packaging the item and then the cost of logistics.

7 Specialist Packaging Solution Tips

To deliver specialist items in a cost-efficient and customer-pleasing way, how you package your item is crucial.

  1. Use Corrugated Cardboard

Corrugated cardboard has a multitude of benefits which make it an ideal material for packaging. The highly-advanced construction of corrugated cardboard means it is strong and durable that can adapt to a range of weights. It also protects against environmental damage such as moisture. Corrugated cardboard is the perfect for the eco-friendly supplier as it is sustainable and easy to recycle. Corrugated cardboard is also lightweight and cost-friendly.

  1. Use The 5cm Rule

In packaging, the 5cm rule is gospel. Firstly, the protective packaging around the item should mean there is 5cm between the product and the edge of the box which helps to prevent under and over filling of protective filler. The 5cm rule also extends to the tape used to seal the box, which should be 5cm wide. A pressure sensitive plastic tape is recommended as it reduces assembly time and is flexible and secure.

  1. Don’t Ship Air

Where possible minimise the empty space in the box, this could be by adapting your product better to fit in the box or, more realistically, finding the right sized boxes. This will save you money in the cost of packaging materials, reduce unnecessary waste and will cut the cost of logistics.

  1. Label Well

While the delicate nature of what you’re shipping, such as mirrors or glassware, may seem obvious to you, logistics won’t be thinking about your product; they just see another box. So if your product is fragile, make it known. It is important to clearly label the box to give an added layer of protection, however never assume a label will protect the box; you need the right packaging too.

  1. Don’t Cut Corners

Having cheaper or a smaller amount of packaging may save you money in the first instance, but it will cost you far more through returns and refunds. In packaging, you need to get it right the first time to give your customers excellent service and to save you money in the long run.

  1. Use A Variety Of Logistic Suppliers

Different logistics companies will use different pricing structure, so you can actually save money by altering your provider depending on what you are shipping. Some carriers will work by weight, others by size, so judge your product accordingly and see the difference in your profit margin.

  1. Continually Improve

Through improving packaging, you will always be able to find ways to save money. Keep a document of lessons learnt and frequent packaging occurrences so you can regularly review the whole process. By building monitoring into your routine, you will always find new ways to improve packaging, reducing your costs and keeping customers happy.

Save Money And Improve Customer Experience With Specialist Packaging Solution, Ribble Right Size

For the right-sized box every time, Ribble Right Size is the specialist packaging solution for you. Right Size allows you, the manufacturer, to produce the perfect sized box every time, whether it is a one-off or a batch.

Ribble Right Size has a significant return on investment as the on demand boxing service allows you to cut costs through wastage, dead space, protective materials, the box itself and the labour intensive task of filling boxes with padding and other protective materials.

Five Benefits Of Ribble Right Size
  1. Reduce logistics costs
  2. Less waste for you and the customer
  3. Eco-conscious and responsible way to package
  4. Less expense (time and labour) spent packing
  5. Customer appreciation – goods delivered without damage.

You can find out more about Ribble Right Size and the benefits it could bring you, by clicking here.

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