Packaging Supplies Blog | Allpack Packaging

Case Study: How the Right Packaging Supplies Reduced Costs for a UK Manufacturer

Written by Daniel Page | Oct 24, 2025 8:00:00 AM

Many UK manufacturers face a costly challenge: the return of damaged goods increases operational expenses. Paint tins and tubs are especially prone to dents, leaks, and movement during transit, leading to wasted stock and unnecessary handling.

 

Through our PaintGuard™ range, we’ve helped a wide variety of manufacturers and distributors overcome these challenges with packaging that combines strength, precision, and sustainability.

The challenge

When packaging isn’t designed for the demands of heavy or irregular products, the results can be expensive. Damage in transit, higher return rates, and inefficient handling are all too common. For businesses handling paint tins and similar goods, these problems are often coupled with the pressure to improve sustainability and cut material waste.

 

Companies have been looking for packaging that offers maximum protection while supporting their environmental goals, whilst remaining cost-effective.

The solution

That’s where PaintGuard™ comes in. This specialist range is designed to safeguard paint tins and tubs throughout the distribution process, ensuring products arrive in excellent condition. Each carton is engineered to hold contents firmly in place, reducing movement and impact damage during transit.

 

Our pulp fitment range complements PaintGuard™ cartons by providing secure, moulded pulp inserts that cushion tins and tubs with precision. Sturdy, robust and perfect for reducing movement in transit, these eco-friendly fitments reduce void space and improve stacking consistency while cutting down on excess material use.

 

Together, these solutions deliver measurable improvements in packing speed, product protection, and waste reduction. With more efficient, recyclable materials, our customers gain both operational and environmental advantages.

The results

Manufacturers and distributors using our PaintGuard™ and pulp fitment ranges have seen clear reductions in damage-related costs and product waste. Deliveries are more reliable, customer satisfaction is higher, and teams spend less time repacking or managing returns.

Better protection means smoother operations, more consistent performance, and stronger supply chain relationships.

Positive environmental impact

Both the PaintGuard™ and pulp fitment ranges continue to evolve, incorporating higher levels of recycled content and more sustainable materials. These developments strengthen environmental performance while maintaining the durability and functionality required for industrial and retail use.

Customers have found that our sustainable packaging options help them reduce waste, cut inefficiencies, and support their sustainability goals without compromising quality.

Our role

We work closely with manufacturers and distributors to assess their packaging performance, identify opportunities for improvement, and implement tailored solutions that make a measurable difference.

Going beyond just protecting products, smart packaging safeguards budgets, maintains customer relationships and improves environmental waste

If you’d like to explore how our eCommerce packaging range could transform your operations and skyrocket your productivity, we offer full packaging audits to help identify opportunities to reduce waste, cut inefficiencies, and improve performance. Get in touch today by sending a message, emailing sales@allpack.uk.com or calling 01543 396 700.