A cost-saving & efficiency-driven packaging project

The Challenge.

A well-established customer was looking to cut costs, rationalise their packaging range, and reduce the annual weight of polythene used across 15 processing sites in the UK.

Their operations had grown organically, resulting in a fragmented, decentralised approach to packaging procurement. Each site ordered independently, creating a large and inconsistent SKU range, unnecessary duplication, and missed opportunities for optimisation.

Recognising the scope for improvement, we conducted on-site Application Audits of their products and processes, which would identify opportunities to rationalise, reduce polythene usage, stock holding and deliver significant cost savings.

At a glance.

Our Objectives

Provide measurable cost savings and reduce polythene waste.
Rationalise many products and condense them down into a range of products that all sites could utilise.
Carry out on-site usage audits using our knowledge and experience of the sites and their processes.
Support the customer in achieving their sustainability goals.
Reduce product numbers and specifications.

The Results

Product range reduction from 120 across 15 sites, to just 20 core products.
25 tonne reduction in the weight of polythene used per annum.

Exceeding the customer's environmental and sustainability targets.
Reduced lead-time to a few days by stocking the core product range.

Annual cost savings in the six-figure range.

Savings through optimisation.

This project represented a significant opportunity to simplify operations and reduce environmental impact. With over 120 different packaging SKUs in use, many of which were performing similar functions, a core range would bring immediate efficiency benefits to the customer's process.

As their packaging partner, we worked closely across all sites to fully understand the full range of product usage and the full cycle of their packaging products. This enabled us to build a data-driven optimisation plan for the customer.

Conducting a thorough analysis.

We began with a full review of product data and usage volumes across the estate. Where information was incomplete, we carried out on-site fact-finding visits, building an accurate picture of how packaging was being used day-to-day.

This revealed more than 120 product types, with considerable variations in size, thickness, and materials, with products being used for similar applications on many occasions.

Alongside this, we conducted detailed Application Audits, mapping the full lifecycle of each product and identifying where technical adjustments could reduce weight and improve efficiency.

Significant benefits through optimisation.

Having the data from the onsite visits, we reduced the packaging range from 120 SKUs down to a core product range of just 20. This rationalisation, once agreed and communicated to all the sites, created immediate operational clarity and consistency across all sites.

This rationalisation project enables us to reduce the customer's polythene weight per annum by 25 tonnes. That’s the equivalent of two articulated lorries of material saved.

The result was a simpler, more efficient, and more sustainable packaging range, delivering substantial environmental benefits and annual cost savings in the six-figure range — all while maintaining product performance and suitability.

Cost Savings, Rationalisation & Product Optimisation.