Blog - The Role of Custom Packaging in Warehouse Logistics

Packaging is a critical part of supply chain success, and custom boxes, crates, pallets and other packaging can save businesses time, space, labour and of course, protect products. In this blog, we'll look at some key challenges of warehousing logistics and how bespoke packaging helps tackle these, as well as factors to consider when implementing a custom packaging solution. 

With the right custom-packaging partner, businesses can protect their bottom line through enhanced logistics performance. Read on to learn how.

Key differences include:

• Custom sizes and shapes to optimally fit products
• Materials selected for protection, sustainability and branding
• Features like dividers, cushioning and reinforced walls for protection
• Ergonomic and automation-friendly handling
• Standardisation for operational efficiency
• Wholesale-oriented branding, labelling and parcel assembly

The core benefit of custom packaging in wholesale is that it can be engineered from the ground up to perform across your handling, storage and distribution environment. This translates into reduced damages, faster processing, lower costs and enhanced branding. The result is packaging optimised for your specific products and workflows. Read on as we continue to explore this in more detail.

Through optimisations across material handling and storage operations, custom packaging delivers immense logistical value for wholesalers operating large distribution centres and warehouses. By tailoring packaging to specific products, workflows and automation systems, wholesalers can enhance productivity, accuracy, speed and even sustainability. 

Key benefits of custom packaging for warehousing and logistics include:

Custom packaging allows wholesalers to select recyclable, renewable and plastic-free materials specifically aligned with their sustainability goals and initiatives. Rather than relying on generic OTS packaging, custom options enable the incorporation of eco-friendly fabrics, upcycled materials, biodegradable composites and other innovative options.

Optimised sizing with a custom design also reduces packaging waste versus OTS options that leave unused space. In addition, sturdier custom packages result in less damage and spoilage in transit, further cutting unnecessary waste. 

For wholesalers supplying major retailers, demonstrating a commitment to sustainability through eco-friendly packaging can strengthen relationships and alignment on CSR initiatives. With growing consumer scrutiny on ethical practices, custom packaging gives wholesalers an advantage in capturing environmentally-conscious market share.

Enhanced Automation and Processing

For modern automated warehousing, custom packages designed specifically for conveyor compatibility and automated handling eliminate jams and errors. With optimised sizing, barcode placement and grip-friendly materials, custom packages integrate smoothly with scanners, sorters, conveyors, robotic pickers and other automation.

This prevents downtime and disruptions while maximising the ROI of warehouse automation investments. Custom packaging can also be designed with features like integrated RFID tags for seamless tracking and monitoring during automated handling. 

Fewer processing errors also translate to greater picking and sorting accuracy, speed and productivity in fulfilment. Automation-optimised packaging gives wholesalers a competitive edge in accuracy and speed when servicing large retail and e-commerce customers.

The upfront investment in custom packaging pays dividends for wholesalers through substantial savings across operations. By reducing product damages, custom packaging decreases write-offs, refunds and rework, saving significantly on overhead costs. Optimised material usage and custom-sized packaging reduce purchasing and inventory carrying costs.

Consolidating SKUs around standardised custom sizes simplifies procurement processes and management while sturdier construction leads to reuse across shipments, lowering packaging consumption. Custom packaging designed specifically for workflows can also boost labour productivity, and even allow for automation-friendly packaging that reduces dependency on manual labour to cut wage expenses.

With a holistic assessment, wholesalers can identify many areas where custom packaging will provide ongoing savings through reduced overheads and improved efficiency. For high-volume wholesalers, these savings quickly multiply across thousands of shipments, leading to strong ROI on the initial packaging investment. Working with an experienced custom-packaging creator like Tidmas Townsend helps businesses get the best deal for their needs.

For wholesalers managing distribution and fulfilment of branded products to retail stores or directly to consumers, custom packaging represents a key opportunity to enable efficient and effective branding. With packaging designed for seamless integration into warehouse workflows, wholesalers can incorporate premium branding elements like textures, graphics and unboxing features without sacrificing processing speed or adding costs.

Custom packaging created for retail partner brands can reinforce desired positioning around quality, sustainability, and innovation while also strengthening loyalty and satisfaction. By collaborating closely with retailers on designing custom packaging that aligns with brand values while optimising logistics, wholesalers can become invaluable partners.

The customisable nature of custom packaging means that establishing a brand experience customers love doesn't have to come at the expense of efficient handling, storage and order processing. With the right strategic approach, branding can complement logistics.

By designing packaging tailored to match warehouse workflows and order profiles, wholesalers can streamline operations for greater speed. Custom cartons engineered for easy access, handling and identification of the most frequently picked items reduce pick times.

Packaging optimised for fast and simple parcel assembly with features like pre-folded flaps and tear strips speeds up packing station workflows and reduces labour costs. Standardisation of custom packaging across products simplifies co-packing and bundling for faster order processing and consolidation, while ergonomic handles and grips reduce picker fatigue and injuries and boost productivity.

This faster throughput translates into improved customer service for wholesalers through quicker order processing, more prompt deliveries and shorter order turnaround times. Custom packaging purpose-built for key workflows gives wholesalers a competitive edge in responsiveness and convenience when serving retail partners and end consumers.

• Lead times: Account for longer lead times when initially ordering custom packaging, which can range from weeks to months depending on complexity. Plan ahead and factor these timelines into launch plans.
  
  
• Upfront costs: Initial design and setup fees for custom tools and dyes make the per-unit cost higher at lower volumes. However, costs can drop as volumes increase, so compare total long-term costs vs. off-the-shelf packaging.
  
  
• Integration: Consider whether custom packaging will integrate properly with labelling systems and collaborate closely with suppliers on label placement, barcode readability and RFID capacity if needed.
  
  
• Performance testing: Rigorously test initial packaging samples with product loading, transit simulation, vibration, compression and other stresses, and tweak until optimised.
  
  
• Rollout plan: Phase a rollout to monitor performance, address issues and refine processes before full implementation, identifying routes and quantities.
  
  
• Change management: Train warehouse and logistics staff on any workflow changes needed for new packaging processes to ensure smooth adoption.

With upfront planning, wholesalers can effectively manage the transition process and maximise value from custom packaging. The long-term gains in protection and efficiency justify the initial investments.

• Reliability in on-time delivery ensures packaging materials are available to meet production and fulfilment schedules
• Consistent quality assurance safeguards the protection of products flowing through distribution channels.
• Technical expertise and customer service provide support in optimising packaging performance.

By aligning with packaging experts dedicated to their success, wholesalers gain strategic business partners beyond just a vendor transaction. This collaboration can allow wholesale businesses to take on bold initiatives in branding, automation and sustainability and strengthen business resilience and responsiveness.

As we've explored, custom wholesale packaging engineered specifically for products, workflows, and automation delivers immense value across warehouse and distribution operations. The wide-ranging benefits, from enhanced protection and efficiency to branding opportunities, ultimately translate into improved service, responsiveness and profitability.

By taking a strategic approach rather than settling for generic off-the-shelf options, wholesalers can gain a competitive advantage. Partnering with an experienced custom packaging provider enables access to technical expertise and creative solutions tailored to your business.

We can help you streamline your warehouse logistics processes with reliable, custom-made boxes as well as printed packaging. Get in touch with our team today to get more information, and subscribe to our newsletter for our latest promotions and offers.