Tag: sustainable packaging

What Manufacturers Need to Know About EPR

Posted on by definitionconsulting

Sustainability regulations are tightening across the UK, and for packaging, this is represented by Extended Producer Responsibility (EPR), pushing retailers and manufacturers to rethink their packaging or face additional costs.

EPR is designed to shift the responsibility of dealing with packaging waste to the companies that produce or handle it. This means that businesses are now obligated to manage the full lifecycle of their packaging, from production to disposal. This is a move aimed at reducing the environmental impact of packaging waste and encouraging the use of sustainable materials. Those who don’t comply or provide inaccurate reporting could be hit with large fines.

How EPR Fees Are Calculated

Only businesses that handle over 25 tonnes of packaging per year and have a turnover of more than £1 million will be subject to EPR regulations.

The fees under EPR are based on several factors, such as the type of material used in the packaging, its weight, and the amount of packaging a company places on the market. Different materials carry different recycling costs, and the fees are reflective of the environmental impact. For example, packaging made from easily recyclable materials like paper or cardboard will incur lower fees than materials like mixed plastics.

Here’s a breakdown of the illustrative base fees for 2025-2026:

What Manufacturers Need to Know About EPR

*Table from Government website – https://www.gov.uk/government/publications/extended-producer-responsibility-for-packaging-illustrative-base-fees/extended-producer-responsibility-for-packaging-illustrative-base-fees

 

When Do EPR Fees Apply?

The EPR regulations apply from the moment packaging is placed on the UK market. For retailers, this means that the packaging used to deliver products to consumers or other businesses will now be subject to these fees. EPR will impact manufacturers, e-commerce businesses, wholesalers, and any retailer that plays a role in distributing products.

Fees will typically apply annually based on the volume and type of packaging handled by the business. Companies will need to submit reports detailing their packaging use and pay fees that cover the environmental costs of collecting, recycling, and disposing of their packaging waste.

Government guidance

For more information on EPR please visit: https://www.gov.uk/government/publications/extended-producer-responsibility-for-packaging-illustrative-base-fees/extended-producer-responsibility-for-packaging-illustrative-base-fees#second-release-of-illustrative-base-fees-for-2025-to-2026

Sustainable Packaging Solutions for Made-to-Order Businesses

Posted on by definitionconsulting

In industries that predominantly operate on a made-to-order basis, such as doors, panels or shutters, rising customer demand for environmental responsibility is pushing manufacturers to rethink their processes. Whether it’s reducing carbon emissions by changing material suppliers or upgrading packaging solutions, companies are increasingly seeking ways to align with sustainability while maintaining product protection, visual appeal and bottom-line profits.

Made-to-Order Packaging

Manufacturers in the doors, panels, and shutters industry cover a wide range of clients, from individual homeowners with smaller orders to large-scale construction projects. Regardless of the order size, packaging plays an important role in ensuring products arrive in perfect condition. Given the intricate finishes and personal details that often define these products, standard packaging solutions frequently fall short.

Traditional packaging practices, such as relying on oversized boxes and plastic void fillers, lead to unnecessary waste, higher costs and a greater risk of product damage. This is where Right Size packaging steps in to provide a more tailored, sustainable, and efficient solution.

The Benefits of Right Size Packaging

Right Size packaging 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.

Case Study: Evergreen Shutters

We recently spoke with Evergreen Shutters, a leading manufacturer who faced packaging challenges due to the variety of custom-made shutters they produced. Standard packaging solutions led to excessive use of filler materials and frequent product damage. Their solution? Implementing Right Size packaging in partnership with Ribble Packaging. You can read the full case study to learn how Evergreen Shutters improved their packaging processes and saw long-term benefits from adopting Right Size packaging.

While transitioning to Right Size packaging is a commitment, the long-term benefits such as cost savings, reduced waste, and improved product protection are undeniable. Adopting made-to-order packaging is not just a practical step but a strategic decision that positions manufacturers for long-term success in a competitive and sustainability-focused market.

Take the Next Step with Ribble Packaging

If you’re ready to discover how custom packaging can transform your business, reach out to us at Ribble Packaging on 0161 284 9000 or through our website. Our team of experts can advise on the best options to meet your business needs, helping you enhance sustainability and reduce costs.

An Update on the EPR Regulations on Packaging and what that means for you

Posted on by definitionconsulting

Extended Producer Responsibility (EPR) has been introduced to reshape packaging waste management in the UK and Europe. If you want to understand more about how this will impact your packaging, then stick around.

As the environmental impact of packaging continues to draw public and governmental scrutiny, EPR regulations are increasingly mandating that producers take full responsibility for the lifecycle of their packaging. Effective from October 2025, these regulations are going to change how businesses approach packaging design, production and disposal.

What is EPR?

Extended Producer Responsibility (EPR) is a framework that assigns producers significant financial and physical responsibility for the treatment and disposal of post-consumer products. The primary goal of EPR is to incentivise producers to incorporate environmental considerations into the design of their products and packaging, ultimately reducing waste and promoting recycling.

Key Changes in the EPR Regulations

The upcoming EPR regulations in the UK bring several key changes that businesses need to be aware of:

  1. Producers will be required to cover the full net costs of managing packaging waste, including collection, sorting, recycling, and disposal. This includes payments to local authorities for handling household packaging waste​
  2. Companies must report on the packaging they place on the market. This data must be submitted bi-annually, covering the volume and type of packaging materials used, to ensure accurate calculation of waste management fees​
  3. Producers will need to obtain Packaging Waste Recycling Notes (PRNs) or Packaging Waste Export Recycling Notes (PERNs) as evidence that their packaging waste has been recycled. This system aims to ensure transparency and accountability in the recycling process​

    More information can be found here (GOV.UK)​​.

Impacts on Packaging Design and Materials

The new EPR regulations are set to also impact how businesses design and choose materials for their packaging. To comply with EPR standards, companies are encouraged to use sustainable and recyclable materials. This shift is driving innovation in packaging design, with many businesses exploring alternatives. In reviewing packaging, many companies have already seen a reduction in excess packaging through Right Size packaging.

While there may be initial costs associated with transitioning to sustainable packaging, the long-term benefits include reduced waste management expenses and improved resource efficiency. Additionally, compliance with EPR regulations can help companies avoid potential fines and penalties. Other benefits have shown companies that adopt sustainable packaging practices can improve their green credentials and appeal to environmentally conscious consumers, demonstrating a commitment to sustainability can differentiate a brand in a competitive market.

Practical Steps for EPR Compliance

Businesses across the UK should start by assessing their current packaging materials and practices to identify areas for improvement. Once identified, work closely with packaging suppliers to develop sustainable solutions that meet EPR standards. Suppliers like Ribble Packaging can offer expertise in optimising packaging and material selection.

Consult the Experts at Ribble Packaging

The EPR regulations mark a significant shift in how packaging waste is managed in the UK. While these regulations pose challenges for businesses in terms of increased costs and compliance requirements, they also offer opportunities for innovation and sustainability. By staying informed and proactively adapting to these changes, companies can not only comply with the regulations but also enhance their environmental impact.

At Ribble Packaging we specialise in providing EPR compliant packaging solutions tailored to your business needs through Right Size Packaging. Contact us today and see how we can help you understand the complexities of EPR regulations.

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

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.

Why Packaging Waste Matters: New Extended Producer Responsibility (EPR) Updates

Posted on by definitionconsulting

The way we package our goods can significantly contribute to a better planet, so it’s no surprise the spotlight is now on sustainability in packaging practices, with updated regulations on packaging waste set to come in October 2025.
These regulations come in the form of Extended Producer Responsibility (EPR), a regulatory framework aimed at changing how we approach packaging waste. Whether you’re sourcing materials domestically or relying on imports, this impending scheme is set to reshape your packaging operations.
This blog serves as an informative follow-up to our previous discussions on the topic, providing the latest updates on EPR.

Understanding EPR

At its core, EPR shifts the responsibility for packaging waste management onto producers, requiring them to bear the full cost of collection, sorting, treatment, and recycling. Recent updates to EPR regulations have brought about significant changes, including the introduction of modulated fees. The payment year has also been deferred from October 2024 to October 2025, however, businesses are still required to declare their packaging waste for 2023.
This initiative is driven by the objective of incentivising producers to limit packaging waste and enhance recyclability. This shift inevitably carries financial implications, as costs are predicted to increase. Therefore, it’s important to understand how EPR will influence your packaging operations and how you can proactively mitigate associated expenses.

Aligning Packaging Practices with EPR

EPR encourages producers to rethink packaging choices and design, urging businesses to embrace recyclable materials and eco-design principles while reducing waste. As companies gear up to comply with EPR regulations, it’s clear that innovative solutions will be essential in meeting these new standards effectively.

How can Right Size Packaging Help?

Right Size solutions combine Ribble’s industry-leading 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, negating the need for void fillers and excess packaging.
We have a simple 4-step process for our Right Size solutions:
1. Enter box style and dimensions.
2. Select how many are required.
3. The box is produced within seconds.
4. Products are packaged in the perfect-sized box.

As well as saving on EPR tax, businesses will save on fuel and transport costs, regain warehouse space and save on labour costs, all resulting in up to 30% savings on packaging costs.
If you would like to discuss EPR in more detail with some of the packaging experts at Ribble Packaging, you can contact us at info@ribble-pack.co.uk or visit our contact page.

Protective & sustainable packaging

Posted on by definitionconsulting

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

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

What are the Ribble Right Size solutions?

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

Create protective and sustainable furniture packaging.

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

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

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

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

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

What are the benefits of using Right Size?

No more excess packaging 

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

Savings on packaging costs 

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

Customer satisfaction 

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

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

How sustainable is your Christmas packaging?

Posted on by definitionconsulting

It’s that time of year again. The time that we do everything in excess, from food, to spending.

But does that mean you have to have an unsustainable Christmas?

As we all know, Christmas can be a time for spending time with loved ones and exchanging gifts, but with it is estimated that around 1 in 4 households will be generating up to 5 bags of rubbish this Christmas!

Much of children’s toys are packaged in plastic or oversized packaging which is bulky and often unnecessary for the size of the present inside. On top of that, there is wrapping paper which, often, you are unable to recycle, which then doubles the amount of waste.

Let’s not forget about the Christmas dinner. Single use plastics have come to the forefront of the sustainable packaging discussion, many of which occur as a result of food packaging.

How can you make your Christmas more sustainable?

It is everybody’s responsibility, to make small changes this Christmas in an effort to reduce the amount of waste created within the household. So, we have put together a few pointers that may help you make some more sustainable choices.

Recyclable wrapping paper

If you’re unsure about what wrapping paper can be recycled and what can’t, it’s important to check with your local recycling centre. Recycle Now have some great pointers on what you can do to ensure that your paper does actually get recycled if accepted at your local centre, including:

  • Making sure all sticky tape, bows and ribbons are removed before recycling
  • Only recycling simple wrapping paper that doesn’t have any glitter or foil as these cannot be recycled.

Present sacks

Another way to reduce the waste this Christmas is to purchase some present sacks & stockings. These can be brought back out every Christmas and eliminate the need to wrap your gifts or find recyclable wrapping paper.

Food & drinks using sustainable packaging

Many supermarkets are introducing refillable packaging services within their stores and this is likely to continue. Why not check out your local supermarket to see if there are any ingredients in your Christmas dinner that could be switched out for a more sustainably packaged option?

Ribble Right Size

At Ribble our aim is to introduce Right Size packaging to more and more manufacturers so that we can help reduce the overall waste when it comes to cardboard packaging.

 

Get in touch today to find out more about the benefits of Right Size.

Packaging in 2022 – The key solutions for the New Year

Posted on by definitionconsulting

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

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

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

Packaging Automation

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

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

Ecommerce Packaging

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

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

Reusable Packaging

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

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

Ribble Right Size

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

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

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

Helping businesses to reduce waste and carbon emissions

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“As terrifying as it is, climate change is setting us on a path of self-destruction.”

Ribble Packaging were delighted to have been able to take part in Insider’s Green Revolution. Discussing and highlighting the importance of sustainability within businesses in the North West and how we can play our part in meeting the challenges of the current climate crisis.

The article discussed how the record growth of ecommerce over the past year has put a huge strain on companies to meet demand, which has meant that we have seen shortages from raw materials to lorry drivers.

Our Managing Director, Stephen Rector, explained; “Boxes are often too large for their products and so they are filled with non-sustainable ‘void-fill’ materials like plastic or polystyrene. It is clearly a hugely wasteful and inefficient method of getting the product out.”

Ribble customers usually see a 30% saving on corrugated costs and recovery of warehouse space with the elimination of obsolete packaging storage.

Stephen went on to discuss the ways in which Right Size packaging solutions can; “Streamline the entire process and mitigates or ideally eliminates void-fill and wastage by making the packaging perfectly sized to fit the product”.

Right Size packaging automation has allowed business over the past year to not have to rely so heavily on manual labour in a time when the pandemic put a serious strain on the labour reliant aspect of supply chains. The introduction of automation has not only encouraged waste reduction, but it’s also allowed businesses to operate in a more efficient, controllable and reliable way.

If you would like more information on how Ribble Packaging could help your business become more environmentally friendly, please contact us today.

The packaging process that is over 99% plastic free

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Internet Fusion Group, a leading lifestyle e-commerce retailer with brands such as Surfdome and Country Attire, have created a sustainable packaging process that is over 99% plastic free. Investments in two Quadient CVP-500 automated packaging machines and switching to Corrugated Fanfold material from Ribble Packaging, have aided with their pursuit of an environmentally sustainable right size packaging process.

To highlight the full extent of their achievements, Internet Fusion have released a report investigating the environmental effects of paper-based packaging versus plastic packaging products. The report explores the full manufacturing process of both paper and plastic packaging, through to the recyclability and long-term environmental effects once a package has reached its destination. Head of Sustainability at Internet Fusion Adam Hall said” Our customers are tired of plastic pollution, and we are tired of the justifications being put forward for continued plastic production in the middle of a marine plastic crisis. When you dig a little deeper these arguments simply don’t stack up, so we felt it was time to share the decision-making process that has led us to our packaging being over 99% plastic free. Our customers choose us because of our environmental efforts and in turn we choose Ribble for the same reasons – it’s partnerships such as these that can shift a whole industry towards a more sustainable future”.

Right Size packaging specialists Ribble Packaging supply Internet Fusion with over 75% of their packaging material in the form of Corrugated Fanfold board, a versatile fully recycled and recyclable cardboard product that feeds many of the leading automated packaging systems in the UK.

Stephen Rector, Managing Director of Ribble Packaging, commented on Internet Fusion’s success: “It is fantastic to see that Ribble products are helping our customers in creating more environmentally sustainable packaging processes. We also see the need to improve our in-house operations to make them more sustainable.”

Earlier this year, Ribble embarked on a project to make their operations carbon neutral. “We understand the need to focus on the effects our manufacturing process has on the environment, this has led to us embarking on a carbon neutral project that will see us embrace new sustainable technologies and practices. Our products allow customers to create a more sustainable packaging process, but we can enhance these benefits by offering a carbon neutral manufacturing process as well.”

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