A high-volume packing operation was struggling to keep pace during peak periods. The problem was not the packaging materials themselves – it was how the whole process worked around them. A structured packaging audit changed the approach from material-led to operations-led, delivering measurable improvements across throughput, productivity and sustainability.
In partnership with Pregis – Samuel Grant Packaging and Pregis work together to combine operational insight with engineered protective packaging, helping businesses improve performance and reduce waste.
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The challenge
On the surface, the existing packaging appeared to be doing its job. Individual products were arriving protected. But the operation behind it was under strain.
- Throughput could not keep up with demand – particularly during peak periods, packing speeds fell behind order volumes
- Pack stations were cluttered and inefficient – poor layout was adding unnecessary handling, slowing operators down and increasing fatigue
- Product protection was inconsistent – a wide range of product sizes made it difficult to achieve reliable, repeatable packing outcomes
These are common issues in busy packing environments, and they often go unnoticed because the packaging itself appears adequate. The inefficiency sits in the process around it.
What the audit found
Rather than reviewing materials in isolation, the packaging audit looked at the entire packing workflow – from material storage and delivery through to how each pack station operated under real conditions.
Opportunities identified
- Simplify how protective materials were delivered to pack stations
- Reduce unnecessary handling and movement
- Improve consistency in how packaging was applied across different product sizes
- Create a more ergonomic, scalable packing environment
What was introduced
Working with Pregis, an integrated paper-based protective packaging system was designed around the workflow rather than individual products.
- Centralised material supply – protective packaging fed to multiple pack stations from a single source, reducing movement and handling
- On-demand paper pads – produced in varying sizes at the point of use, matching protection to each product without over-packing
- Reconfigured workstations – redesigned for better space, access and operator efficiency
- Recyclable, high-performance paper materials – balancing product protection with sustainability goals
The system was designed to support current demand and future growth, while reducing reliance on manual processes.
What changed
Measurable improvements across the operation
- Increased throughput – packing speeds improved significantly, particularly during peak periods
- Improved productivity – reduced handling time and better material accessibility meant packers worked more efficiently
- Better ergonomics – cleaner, better-organised workstations improved comfort and reduced unnecessary movement
- Consistent product protection – on-demand sizing ensured appropriate protection across a wide range of products
- Fewer operational interruptions – less downtime, better workflow continuity
The wider picture
By taking a system-wide view, the business moved from a material-led approach to an operations-led one. The result was not just better packing performance – it was a more scalable, efficient and sustainable process overall.
This reflects a shared approach between Samuel Grant Packaging and Pregis: combining operational insight with engineered packaging to improve performance, reduce waste and support long-term efficiency.
A packaging audit looks beyond unit cost
This is where a packaging audit adds real value – identifying opportunities that are often missed when focusing on individual products alone. The right assessment considers:
- Workflow efficiency and throughput
- Labour, handling and operator ergonomics
- Material usage and waste
- Consistency and performance in real-world conditions
Not just the cost per item. Packaging decisions that focus only on unit price often miss the larger operational picture. A packaging audit brings that picture into focus.
Is your packing process holding you back?
Many operations experience the same challenges without realising the root cause sits within the packaging process itself. If any of this sounds familiar – throughput constraints, inconsistent protection, cluttered pack stations, rising handling costs – it is worth taking a closer look.
A structured packaging audit can help uncover:
- Hidden inefficiencies in packing workflows
- Opportunities to improve throughput and productivity
- Material and cost savings
- Improvements in sustainability and compliance
Talk to us about a packaging audit
A practical, on-site review of your packing process – with clear findings and next steps.
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