The Benefits of Eliminating or Reducing Corrugate in Secondary Packaging

28 April 2015 //

Double Tight WrapLDPE

When was the last time you drove around the back of a large big box retailer or the local grocery store and saw large, strapped bundles of corrugate stacked just waiting to be picked up?

Now, consider the costs associated with each of the cardboard containers within that bundle:

  • The initial cost of the cardboard box itself
  • The cost of housing the cardboard
  • The amount of space consumed prior to packaging
  • The cost associated with the weight when shipping
  • The cost of the space consumed by the waste after product has been placed on the shelf
  • The cost of the carbon footprint to not only make, but to recycle cardboard

Eliminating or reducing corrugate in secondary packaging not only decreases costs, it also provides benefits to all members of the supply chain:

Product Manufacturer

Manufacturers benefit the most when corrugate is reduced or eliminated, with one of the first benefits being an increase in available space. Corrugate must be stacked and stored prior to use, which takes up valuable space in a warehouse or manufacturing floor.

Film rolls, while also needing to be stored, take up 90% less space compared to corrugate and its wrapping capacity. Bundling and shrink-wrapping products also offers greater flexibility for multiple pack sizes and can increase throughput. In some instances, where manual packing is being replaced by an automatic process, labor redistribution costs can be achieved. In addition, manufacturers that reduce or eliminate corrugate can create a denser pallet.

In cases where a bagged product is bundled, EDL’s Double Tight Wrap allows product to be palletized without overhang and stacked higher than traditional wraps. In both instances, overall transportation costs are reduced.

Distribution Center

Once a pallet arrives at a distribution center it is typically stored or broken down for secondary distribution to regional warehouses or stores. Distribution centers also benefit by reducing the amount of waste material when the secondary pack is opened for a higher level of distribution. Product handling and transportation costs are also improved.

Retail Store

Think back to that bundle of corrugate. It has to be stored somewhere.

Retailers are one of the greatest drivers of eliminating corrugate. Since many retail stores do not have enough space to store the amount of product needed to meet consumer demand, distribution centers must deliver products on a weekly or bi-weekly basis. These shipments translate into excess corrugate that must be broken down and stored, taking up valuable space. Shipping costs are also increased and are passed on to the end consumer.

Since waste film takes up less space, retailers do not need to schedule recycling pickups as often, resulting in fewer pick-ups and less gas consumed. In addition, LDPE uses less energy to make and recycle than corrugate, because it is derived from natural gases.

Whether retailers are driving you to reassess your secondary packaging solutions or you are you looking to simultaneously save green and go green, EDL can help assess and identify the best secondary packaging solution for your products. Whether your products are bundled and shrink-wrapped or picked and placed into a tray for stability and then wrapped, our packaging machines are tailored to meet your exact needs.

Contact our team to learn how we can help you eliminate or reduce the volume of corrugate you’re using.