Guest Edited by Sam Botterill, Customer Satisfaction Manager at SmartShield
In industrial packaging, efficiency is everything. The right packaging process reduces waste, cuts costs, and improves shipment protection, but an inefficient process leads to wasted labour, wasted materials, and unnecessary expenses.
At SmartShield, we analyze packaging workflows to identify opportunities for streamlining operations, reducing damage rates, and optimizing costs. Here are four proven ways to improve your packaging process today.
1. Eliminate Wasted Labour
Wasted labour is one of the biggest bottlenecks in packaging operations. It slows down productivity, increases costs, and often results in inconsistent or ineffective packaging. Common causes include:
- Inconsistent packaging methods – different staff use different techniques, leading to inefficiencies.
- Using multiple materials unnecessarily – wrapping products in two layers when one would be enough.
- Manually wrapping items instead of using custom inserts – wasting time securing items when a pre-cut foam or cardboard insert would work better.
- Lack of proper equipment – inefficient manual processes that slow down throughput.
The Fix:
- Train staff to follow a consistent, standardized packaging process
- Use custom-designed inserts to reduce unnecessary wrapping and improve protection
- Implement laminated packaging products (e.g., bubble wrap laminated to foam or paper) to avoid double wrapping
- Invest in dispensers and automated equipment (more on this below)
2. Reduce Wasted Materials
Using too much packaging or the wrong-sized materials leads to higher costs and inefficient shipping. You could be paying more for materials, extra shipping fees, and even storage inefficiencies.
Common Causes of Material Waste:
- Oversized packaging – using larger boxes than necessary leads to wasted space and extra void fill.
- Inefficient design – poorly sized packaging requires excessive taping or additional protection.
- Overpacking – using too many layers or unnecessary cushioning adds to costs.
The Fix:
- Use right-sized packaging to eliminate void fill and excess material.
- Upgrade from open-ended bags (which require stapling/taping) to reclosable, peel & seal, or heat-sealed bags
- Swap manual labeling for custom-printed packaging with pre-applied handling instructions
3. Invest in the Right Equipment for Faster Packing
Many companies rely on manual processes when simple equipment upgrades could save hours of labour and improve consistency.
Essential Packaging Equipment for Efficiency:
- Bubble and foam dispensers – quick, controlled access to protective materials.
- Kraft paper and poly film dispensers – reduce material waste and speed up packing.
- Strapping dispensers and seal-less tools – replace slow, multi-step tensioning and sealing processes.
- Loose fill hoppers – make void fill application faster and more efficient.
For high-volume operations, consider automating some processes:
- Tape dispenser → Case taping machine
- Stretch wrap dispenser → Stretch wrapping machine
- Heat gun → Heat shrink tunnel machine
- Manual stapling → Pneumatic staplers
These small upgrades can dramatically increase packing speed, improve consistency, and reduce labour costs.
4. Optimize Material Design for Faster Packing and Shipping
Sometimes, packaging improvements go beyond materials and machines—design plays a key role too.
Easy Wins:
- Switch from loose fill void fillers to custom-fit inserts for faster, neater packing
- Use pre-printed packaging with handling instructions instead of applying separate labels
- Implement colour-coded sealing tape or stretch wrap for quick identification of different product types
- Use multi-purpose packaging—for example, one custom-printed box that works for multiple products, with checkboxes to mark the specific contents
These simple design upgrades can speed up shipping, reduce packing errors, and improve customer experience.
Okay, we’re going to sneak in a fifth tip, which is to give our experts a call to help you streamline your packaging processes!
5. Use SmartShield!
We’re experts in delivering custom-engineered packaging solutions, including:
- Custom inserts and fitments
- Right-sized, high-performance materials
- Strategic packaging support
Conclusion: Small Changes make a Big Impact
Streamlining your industrial packaging process doesn’t have to mean a complete overhaul. Often, small but strategic changes, like using correctly sized materials, upgrading equipment, or adopting custom inserts, can have a huge impact on efficiency, cost savings, and product protection.
At SmartShield, we specialize in helping businesses like yours eliminate waste, reduce labour costs, and improve packaging performance with custom solutions designed to fit your needs. Whether you’re looking to fine-tune a single step or optimize your entire process, we’re here to help.
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Ready to make your packaging smarter, faster, and more cost-effective? Let’s talk.