Packaging Audit for Cost Reduction and Operational Improvement
Why the Packaging Audit Was Requested
A leading supplier in the bakery trade sought a packaging audit to enhance their packaging operations and reduce costs. Known for serving various sectors including craft, commercial, and artisan bakers, as well as retail and food service, this supplier is recognized for being an innovative development partner.
The supplier offers over 600 world-class products. providing exceptional customer service with next-day delivery, flexible ordering, and technical advice from experienced bakers. They also maintain an active innovation and education program to stay ahead of industry trends and offer an extensive range of packaging and accessories for convenience.
The audit aimed to identify opportunities for improving packaging efficiency, reducing material usage, and achieving cost savings while maintaining high standards of product protection and service. The findings highlighted several improvements, including the transition to advanced nano-layered stretch film, which significantly boosted cost efficiency, operational productivity, load stability, and sustainability.
Audit Findings and Comparative Analysis
Key Comparisons and Improvements
1. Cut & Weight Reduction
- Current Film: 500 x 23 microns, weighing 366g per cut.
- Trialled Film: 500 x 15 microns, weighing 156g per cut.
- Improvement: A remarkable 57% reduction in weight, which directly translates to material savings and less plastic usage.
2. Cost Efficiency
- Cost Per kg: Reduced from €3.15 to €2.88, an 8.5% saving.
- Cost Per Roll: Reduced from €50.40 to €46.00, an 8.5% saving.
- Cost Per Wrapped Pallet: Dropped from €1.26 to €0.45, a substantial 64% reduction, demonstrating significant cost-efficiency.
- Weight per Roll: Both films weigh 16 kg, ensuring no additional handling burden.
- Wrapped Pallets per Roll: Increased from 40 to 102 pallets per roll, a 155% increase. This means fewer roll changes and higher productivity.
Meeting Critical Business Needs
Cost Efficiency
This Company, like many companies, operates in a cost-sensitive environment where every euro saved impacts the bottom line. Our audit revealed that by switching to the nano-layered stretch film, significant cost reductions were achievable:
- Cost Per kg: Reduced from €3.15 to €2.88, yielding an 8.5% saving.
- Cost Per Roll: Lowered from €50.40 to €46.00, also an 8.5% saving.
- Cost Per Wrapped Pallet: A dramatic drop from €1.26 to €0.45, a 64% reduction. This substantial saving enhances the cost-effectiveness of each wrapped pallet, allowing This Company to allocate resources more efficiently.
Operational Efficiency
Efficient operations are crucial for maintaining productivity and reducing downtime. Our nano-layered stretch film offers significant improvements in this area:
- Weight per Roll: Both films weigh 16 kg, ensuring no additional handling burden.
- Wrapped Pallets per Roll: Increased from 40 to 102 pallets per roll, a 155% boost in efficiency. This increase means fewer roll changes, resulting in less downtime and higher productivity. Employees can focus more on other critical tasks rather than frequently changing rolls.
Load Stability and Product Protection
This Company deals with various pallet load profiles, including the challenging Type C loads, which are irregular and prone to causing wrap tears. Our nano-layered stretch film excelled in this area:
- Enhanced Durability: The multi-layered structure of the nano film provides superior strength and puncture resistance, ensuring even the most irregular loads remain secure during transit.
- Tension Adjustment: We recommended reducing the wrapping machine tension, as the nano film’s reduced thickness and softer lay-on force help maintain load stability without compromising protection. This adjustment reduces film breakage and ensures consistent wrapping quality.
Sustainability
This Company is committed to sustainable practices. Our nano-layered and PCR (Post-Consumer Recycled) stretch films support their green initiatives:
- Reduced Plastic Waste: Using less film without sacrificing performance leads to lower plastic consumption and waste.
- Eco-Friendly PCR Films: These films are made from recycled materials, supporting a circular economy and reducing reliance on virgin plastics. They offer the same mechanical performance as traditional films while maintaining full recyclability.
- Compliance with EU Regulations: By using PCR content, This Company can reduce financial and environmental costs associated with non-recycled plastic waste, aligning with EU environmental goals.
Delivering Exceptional Customer Satisfaction
Our audit and the subsequent implementation of the nano-layered stretch film have resulted in highly positive feedback from This Company:
- Customer Testimonials: Customers have expressed satisfaction with the cost savings, improved efficiency, and enhanced load stability. They appreciate the reduced downtime and the seamless integration of the new film into their operations.
- Sustainability Goals: This Company is pleased with how the switch aligns with their sustainability targets. The use of eco-friendly PCR films reflects their commitment to environmental responsibility, which has been well-received by their stakeholders and customers.
- Ongoing Support: Our continuous support and monitoring have ensured that This Company maximises the benefits of the new stretch film. Any necessary adjustments are promptly addressed, ensuring consistent performance and customer satisfaction.
3. Operational Efficiency
Conclusion
The audit for This Company highlights the significant benefits of switching to our advanced nano-layered stretch film. From cost savings and operational efficiency to enhanced product protection and sustainability, this innovative packaging solution addresses the critical needs of modern businesses. By partnering with Hub Packaging, This Company can confidently move towards a more efficient and eco-friendly packaging process, ensuring long-term success and sustainability.
Embrace the future of packaging with our nano-layered and PCR stretch films, and experience the transformative benefits for your business.
The transition to nano-layered stretch film has proven to be a strategic move for This Company, addressing critical business needs and driving significant improvements in cost efficiency, operational productivity, load stability, and sustainability. The positive feedback and high satisfaction levels from our customers underscore the value of this innovative packaging solution.
At Hub Packaging, we are dedicated to helping businesses like This Company achieve their goals through tailored, high-performance solutions. Partner with us to experience the transformative benefits of advanced stretch film technology, and join the ranks of our highly satisfied customers.
