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The ABCs of Sustainability in Industrial Packaging

A festive photo with a stack of three boxes wrapped in kraft paper with dried fruit on top with Christmas lights in the background.

The holidays are upon us and those UPS, FedEx and DHL deliveries are about to stack up quickly. It is estimated 40% of the worlds plastic waste comes from packaging alone – whether it be food, electronics, medical, home goods or other. But, sustainability in industrial packaging isn’t just about using less or finding more recyclable options – it encompasses a 360 degree view from where the raw materials originate all the way to a community’s disposal infrastructure. We put together the “ABCs of Sustainable Packaging Terms” to help provide a broader perspective to this growing topic.

Before we get into it, let’s discuss some of the pitfalls when it comes to sustainability in an industrial packaging wholesaler. Colony strives to be transparent and upfront when it comes to what is and is not sustainable packaging and our role as your distributing partner in it. We don’t fit the expectation into the industry, instead we present the real facts backed by science to support the expectations. Here we highlight products and claims which as packaging experts we don’t consider fully sustainable options.

  • Biodegradable Plastics: While biodegradable plastics have gained popularity for their potential to break down more quickly than traditional plastics, they often require specific conditions, such as industrial composting facilities to decompose fully. In the absence of these conditions, which is more common than not, materials will still persist in the environment, contributing to pollution.
  • Single-Use Compostable Packaging: Similar to biodegradable plastics, compostable packaging items like plates, cups, and cutlery need specialized composting facilities to break down properly. When disposed of in regular waste streams or landfills, they will not biodegrade as intended.
  • Paper Packaging with Non-Recyclable Coatings: Some paper packaging products come with non-recyclable coatings or laminates that make them difficult to recycle. These coatings can contaminate recycling streams and hinder efforts to reduce waste.
  • Packaging with Excessive Greenwashing: Some manufacturers and top packaging suppliers may overstate the environmental benefits of their products through greenwashing. This can mislead consumers into thinking they are making sustainable choices when, in fact, the product’s overall impact on the environment remains high. An example of this could be products with biodegradable additives – the language sounds great but the reality is not.
  • Heavy, Bulky Packaging: Packaging materials that are unnecessarily heavy or bulky can result in higher transportation costs and increased emissions. While they may not explicitly market themselves as sustainable, their inefficiency in resource use contradicts sustainability goals.
  • Products Lacking Certification or Transparency: Packaging products claiming to be eco-friendly should ideally have certifications or clear documentation to support their sustainability claims by trusted third party sources. Lack of transparency and verifiable information can raise doubts about a product’s true environmental impact.
  • Excessive Packaging: While not limited to a specific material, the practice of over-packaging products can lead to unnecessary waste and resource consumption. Companies may use excessive packaging to enhance product aesthetics or safety, even if it’s not environmentally justified. Colony Packaging excels in package conversion to reduce this waste.

Evaluating your packaging materials with three things in mind when it comes to sustainability goals on a very basic level could include:

  • Use packaging which decreases or eliminates damage rates
  • Reduce overall packaging to the greatest extent possible
  • Consider curbside recyclable options to make it easier on the consumer to recycle materials

Sustainability in packaging can be quite extensive – looking for additional ideas? Here are our industrial packaging supplies company ABCs of Sustainability:

A – Analytics: Colony Packaging & Machine will help you make better decisions with data-driven insights for optimizing packaging processes as it applies to labor savings, decreased material usage, increased material effectiveness, overall safety and sustainability concerns.

B – Biodegradable: Colony can help distinguish packaging materials that decompose naturally versus smoke and mirrored marketing so you get exactly what you think you are getting.

C – Circular Economy: A system aimed at eliminating waste through the continual use of resources.

D – Durability: Colony focuses on the ability of packaging to withstand the rigors of transport and storage to decrease or eliminate damage or returns. This process is naturally focused in sustainability, but with an added bonus of recognizing materials that are also physically sustainable can increase this effort two-fold.

E – Eco-friendly: Colony can work with you to recognize the best packaging that does the least harm to the environment from raw material sourcing, labor considerations to the manufacturing process to the ability for the end user to recycle the material successfully curbside.

F – Footprint Reduction: Whether it be increased packaging equipment efficiencies or custom warehousing for power savings or strategies to minimize environmental impact through decreased material usage, Colony has multiple avenues to explore an overall footprint reduction.

G – Green Certification: Colony can provide documentation regarding standards that verify sustainable practices in packaging from manufacturers when available.

H – Hazardous Materials Compliance: SDS/Tech data is always available from Colony’s vendor partners to ensure packaging meets safety regulations for hazardous substances.

I – Innovation: Colony is very focused on new technologies and materials for sustainable packaging solutions and bringing those solutions to our customers for consideration.

J – JIT (Just-in-Time) Delivery: We reduce deliveries from our manufacturing partners and to our customers by offering a large stocking program and dedicated, scheduled runs to best decrease unnecessary fuel usage.

K – Kraft Paper: A key sustainable choice which has quite a lot of possibility through Ranpak’s extensive line of kraft paper converting equipment. Kraft paper is a great resource for blocking, bracing, cushioning, and void fill.

L – Lifecycle Assessment: Work with Colony to evaluate the environmental impact of packaging from creation to disposal. This includes raw material sourcing, the manufacturing process, deliverability, curb-side recyclability and more.

M – Minimalism: Colony promotes using the least amount of materials necessary to achieve functionality while decreasing damage rates. Continued innovation within packaging materials makes this possible.

N – Natural Materials: Colony can help distinguish fact from fiction when it comes to sourcing packaging from organic, renewable resources.

O – Optimized Design: Colony offers a large knowledge base across industries to streamline packaging to reduce materials and waste.

P – Post-consumer Recycled Content: Utilizing materials that have been recycled after consumer use is a great way to get one-time use materials out of the landfill and back into the supply chain – Paragon offers a patented PCR stretch film which meets these qualifications.

Q – Quality Assurance: Ensuring sustainable packaging meets high standards without compromising safety can be done through third party evaluations, but the best route is through direct conversations with us at Colony and our specific vendor partners supplying your material – the information will be more accurate, complete and goal-oriented.

R – Reusable Packaging: Colony can connect you with designs that allow for multiple uses before disposal and also reusable closed-chain packaging containment solutions like pallet wraps, containers, and more.

S – Sourcing: Work with us to outline your ideal responsible procurement methods from sustainable sources, and we at Colony can help present options which get you there.

T – Transparency: Our team at Colony wants to work alongside you to reach clear communication about materials and processes used/required in your packaging.

U – Upcycling: We love a good repurposing of packaging materials for new uses and so do your customers.

V – Value Chain Optimization: Improving the efficiency of packaging processes throughout the supply chain.

W – Waste Reduction: Colony works with our customers on strategies aimed at minimizing packaging waste – in turn this should lead to decreased damage and faster outputs.

X – X-factor Sustainability: This can include unique sustainable features that differentiate products in the market – to help share that information with your customer base consider adding an interactive QR code to help elevate your message.

Y – Yield Improvement: A key factor Colony is focused on is enhancing the efficiency of material use in your packaging.

Z – Zero Waste: A commitment to eliminating waste in packaging production and disposal.

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Top Packaging Trends for 2024

Being an industrial packaging wholesaler doesn’t always give us the chance to celebrate the more colorful, fun side to consumer packaging. But, with the start of the year it is that time we highlight some of the best packaging trends we are seeing across the consumer industry and showing you how it can translate to the industrial world.

Smart Packaging

Sound familiar? It should – smart packaging has been around for quite a while with amazing innovations continuously coming to market. We’re not just talking about interactive QR codes or RFID tags for tracking in logistics. Smart packaging has grown substantially across industrial and consumer applications, including custom warehousing, moisture control, time-temperature indicators, and immersive technologies like AI and virtual reality.

How to incorporate in the industrial space: database-driven multi-line marking and coding offers superior quality and does not come with the service contract headaches you might be used to. Alternatively, labels and custom printed boxes can be a great addition to add smart packaging or cold seal packaging machine to your industrial line.

Anti-Theft Packaging

Anti-theft packaging isn’t new, but with its combination with smart packaging manufacturers are fighting back against in-store theft, porch pirates, and even theft at the plant. Reinforced water-activated tape is the most popular for in-transit shipments before they hit someone’s door, but things like black shrink film and plain packaging options for e-commerce deliveries are becoming popular again to fight porch pirates. Locking tab boxes, clamshells, and skin packers can all help anti-theft measures at the plant and in-store on the shelves.

Biodegradable Packaging

The continuous growing trend of biodegradable packaging is everywhere. As we have deeper conversations with  customers and manufacturers it is important to note the industry has a long way to go until there are truly biodegradable packaging options in the marketplace. As consumers demand change, customers and manufacturers are teaming up to deliver solutions getting us closer to truly biodegradable options. If you are in the market for this type of product there are some key questions you should be asking the manufacturer before assuming the non-regulated term “biodegradable” is matching your expectations:

  • What environment does the packaging need to be in to biodegrade (and is that environment available to your end user)?
  • Is there a trusted third party certification the manufacturer can present? What does that certification say – will it fully degrade or partially degrade? In what timeframe?
  • What materials are being used to make the packaging and what does that sustainability stream look like? Are the raw materials being sourced sustainably?

Sometimes the best answer is finding curbside recyclable and reusable packaging that your end users can easily handle across different states / local municipalities. Another answer could be to use more efficient packaging which is inherently more sustainable by nature!

The Packaging We Want to See Graveside as Consumers:

Our vendor partner Sealed Air offers a variety of mailers with tear strip convenience!

We all know we get packages in the mail that we just say – but why? Some of those answers while working in fulfillment are easier than others. But, we can all appreciate a little chuckle over silly frustrations whether our company is committing them or not – here are ours!

Mailer bags without a tear strip for easy opening: For the everyday consumer it is like the best invention since sliced bread. The convenience is an easy slam dunk!

Small items in over-sized cartons: Give us a small padded mailer and call it a day – it helps with shipping costs and lowers our trash on collection days. Right-sizing is better for everyone!

Food packaging with ziplocks that rip the bag or without the little quick open notch: We love a good reusable food bag, but when that pesky ziplock feels more like a glue lock it can sadly rip that bag and make it harder to close. No more glue lock ziplocks!

Tough packaging for kids toys – whether it is sharp edged clamshells without easy open tabs with a smooth edge or a significant amount of twist-ties that can cause choking hazards – it’s hard being a parent with an excited child jumping on top of you trying to open and keep track of little packaging pieces.

and finally….

What We Are Looking Forward to in 2024 – Vendor Highlight

Paragon Films has been working hard on creating a stretch film with greater percentages of PCR – post consumer recycled content. With patents in hand they are the only stretch film on the market truly living up to the more modern take on sustainability goals delivering 25% PCR in the new Power Edge PCR Hand Stretch Film. This film focuses on the PCR content while continuing the trend of modern stretch film technology with a thinner gauge film. This film is a true game-changer when it comes to sustainability goals.

Paragon is removing used stretch film from the waste stream and putting it back into new usable film.  Paragon estimates 1.5 billion tons of stretch film was produced in North America in 2020 with only a 16% recycled rate – only 1% being recycled into stretch film. Their goal is to increase both of those percentages while delivering a superior stretch film. Interested in learning if this film would be a good fit for your packaging line? Contact Colony Packaging & Machine!

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Branded Packaging That Makes Cents

Whether you’re a B2B or B2C company your company’s reputation keeps them coming back. When it comes to that reputation the easiest leave behind is within the branding itself. How do you know if branded packaging is right for you? It’s a common phrase of manufacturers, retailers, and industrial packaging wholesalers: “If you have a competitor in the marketplace, it’s right for you.” But, you want packaging that makes sense (and cents). Here are our easiest packaging upgrades to take advantage of this year when working with your marketing and operations departments:

Printed Boxes
We love these bold examples of printed RSCs and tuck tab boxes. The creative use of negative space can give your brand a bolder look with less ink coverage!

One color logos and branding look memorable pre-printed on cartons and are an easy upgrade with reasonable quantities. Can’t do all of your boxes? Consider stocking your highest moving box with your logo for the best ROI. Or, do you have different ordering methods like indirect (through a retailer) or direct (through Amazon, Ebay, Etsy, etc)? Deciding to tackle the direct sales first can give you the highest level of ROI. Plus, we now offer full color printing for orders of 250 or more without printing die plate charges. Our partnership with a leading box manufacturer allows us access to an 80 ft printing press – the only one currently operational in the United States with short lead times.

 

Printed Tape
1-2 color tape print with bold fonts or large imprint logos direct the eyes of customers straight to your package!

Bold coloring, font, and logos make any kraft or white carton pop in shipping and on the doorstep. To gauge the popularity of printed tape ask yourself, “When was the last time you saw a box on your front step without it?” One way to do that is through one of the most popular options – Water Activated Tape (WAT). But, did you know “back in the day” water-activated tape had all but died off in the packaging industry during the 1970s? It was actually invented by Thomas Edison in 1912 and was a replacement for twin when holding boxes closed. It was revolutionary for a long time until acrylic and hot melt tape technology took over. But, because of Amazon, WAT tape made a huge comeback 10 years ago and is now one of the most popular ways to brand a box easily and effectively. We offer low 5-case minimums for both WAT and hot melt custom printed options!

 

Master Carton Messaging
Our partner Matthews Marking shows three of their top marking technologies clearly with this example of piezo, thermal and DOD inkjet. Line sharpness and custom warehousing scalability make Matthews a top fit for small to x-large companies.

This is a great option whether you work directly with your end-user or through a third party shipper. Craft your customer service experience to your audience with QR code surveys, additional product info, or current promotions/product releases with multiple inch print. Or, if you are a co-packer, increase your value by quickly changing customer messaging based off who you are packing for. Marking and coding on demand has been revolutionized in the last few years from the inks and equipment to the technology capabilities for usability. Pre-program messages based off the line you are running or work with our partnered engineers to scale your messaging based off database information. Master carton messaging has been a game changer for food manufacturers, building suppliers, agricultural, and more in particular.

 

Printed Stretch Film
How is your brand standing out in the racks? Printed stretch film can make your wrapped pallet a sitting billboard in an otherwise crowded space.

We’ve seen an increase in popularity for printed stretch film for top packaging suppliers to wholesale clubs, manufacturers that ship on flat beds, and for building and landscaping products that sit outside fully wrapped until use like mulch and bricks. That material is your free billboard space on the road and in the racks. Thinking of printed stretch film, we also work with companies that want to quickly identify products on their floor for returns, hazmat, or other specialty considerations through tinted films like red or green. Whether it be hand film or machine film we have the options to get the messaging you want across internally and externally.

Industrial branding looks different for everyone, and these are just a few examples we offer solutions on. We can help elevate your branding from the label to the pallet. Give your salesperson a call to start the discovery process – your competitor already has!

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Fighting Packaging Damage Like a Pro

Damages in packaging can sometimes feel never-ending. It usually costs companies twice as much as they realize because for every touch point of the return it takes away time processing and churning out new orders. As one of the top packaging suppliers, we break down some of the areas you can familiarize yourself with to better prepare your team to tackle those damage areas:

Shipping Boxes

One of the most important places to start looking for damage is with the shipping box. It is the easiest thing for a buyer to shop around for but not all boxes are created equally. Knowing the differences and creating a standard for your company will be imperative to low to zero damage rates.

Strength

Cartons are measured in strength in two ways: Edge Crush Test (ECT) or BS (Burst Strength). Both can also coincide with wall thickness like singlewall, doublewall, or triplewall.  ECT is going to tell you the overall stacking strength of boxes. If you are palletizing or oftentimes stacking a lot of product on top of one another and the box corners are collapsing you might need a higher ECT box. The BS measurement is how much internal or external pressure it takes to damage the side walls of a carton. ECT and Burst Strength are not interchangeable although many places only offer one or the other and will substitute with them. But, keep an eye on this factor especially if damage has creeped up seemingly out of nowhere.

Box Type

Box types are going to offer different reinforced angles. The standard RSC is universally great, but right-sizing your box and looking at how an item is packed could get you in a better fitting box.

Recycled Content

More and more often we are finding higher rates of recycled content in boxes. Almost all boxes have at least a small amount of recycled content but when you have boxes with higher percentages the fibers are shorter and the overall box is going to suffer in strength.

Tape/Sealing

How you seal your box could impact the overall integrity of the box. Choices can range from glue, acrylic, hot melt or water activated tape. Each has different strengths (and weaknesses) depending on your production line, atmosphere, and long-term storage. We look at the weight of your product, the temperature you seal and store your products (short or long-term), and the type of box you are sealing when making a tape recommendation. Not all tapes fit every application, and your box impacts the type of tape you can use more than you might think.

Void Fill & Cushioning

 

Void fill and cushioning are generally both used within a shipment but aren’t always different items. The UPS/FEDEX rule of thumb is to allow 2″ of cushioning between the item and the box wall. That cushioning can be the same material you wrap your product with or it can be void fill to eliminate that extra space for the product to shift into during

This box shows items inside the box secured with void fill at the top of the box to prevent shifting during shipment.

shipment. Void fill can be foam, crumbled paper, or airbags whereas cushioning is oftentimes bubble wrap, foam molds, or paper pad wrapping.  We see customers use a combination of both with great success.

Package Weights

After everything you have learned so far about fighting packaging damage the package weight will help direct you to what kind of carton, tape, and void fill/cushioning you will ultimately need to be successful. It is important to also look to see how the weight is distributed in the box to prevent hard shifts during shipments or excessive pressure on the bottom or top of the box as easy breaking points.

Protective Packaging

If the damage is occurring on the item itself it may just be you need a simple poly bag or protective film to help protect the surface from those friction marks. This extra barrier between your product and the packaging can make a big difference in damage reports by end-users.

Shipping Methods

How you ship your product might tell you how much protective packaging you may need. For instance you might be delivering products on your trucks and not need to think about hard shifts from tumbling down a conveyor belt in a distribution hub. But, if your product has any chance of going on a common carrier it is best to pack for those instances. Customers may not tell you they re-shipped your product, but they could still claim damages if shipped along to their own end-user.

Pallet Configuration

This last area for damage may not apply to you, but if you are palletizing your products to ship out it is important to look at how the items are getting stacked and secured. You could have an A, B or C load and all of them have different considerations. For instance if you are using stretch film on an A load with light-weight items you will need a stretch film that doesn’t crush the corners. Or, if you are shipping a C load you might need a film that has high puncture resistance for sharp, out of place corners to connect between layers. Recognizing these vulnerable shipments will help you budget appropriately for successful shipments everytime.

Damage can occur anywhere in the packing and hipping process. Now that you know some of the highest areas of damage in packaging you can make more predictable, long-term cost saving decisions for your company.

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THIS or THAT: Our Top Packaging Alternatives During Supply Chain Shortages and Beyond

The last couple of years the supply chain dilemma every industry has faced has had us thinking creatively and reminding our Sales Reps of that initial customer call where the drawing board is a little empty and ready for development. Our industry experience and longevity in the field have lent itself well as Colony Packaging & Machine navigates the future and recommends alternative packaging solutions. Fluctuations in pricing continue and lead times across industries shift at any given time, but these alternatives can help you think more creatively and broadly about your packaging applications to give you back power in the sourcing and decision-making process. Here are some of our top THIS or THAT options – packaging edition.

Strapping OR Bundling Stretch Film, Titanium Stretch Film

Titanium stretch film is a top-rated banded stretch film to help with ultra-heavy loads. This film can replace certain types of strapping for hard to manage loads.

When it comes to bundling products or strapping uniform skids modern stretch film can be a key alternative. Bundling stretch film comes in high gauges and is a compact, easy substitute to strapping. Similarly, we offer a high strength stretch film which is newer to the market. This titanium stretch film has heavier bands that create a strapping-like retention to the pallet which creates a stable load for shipping. Customers who have tested this film admit they haven’t seen anything like it on the marketplace.

Corrugated Cartons OR Mailers & Branded Mailers

Between our in-house carton stock, drop ship program, and custom box capabilities we offer a large range of solutions for customers seeking out shipping boxes. However, as e-commerce continues to boom many top packaging suppliers offer products in ready-to ship boxes that could be slipped into a mailer versus additional corrugated boxes. Mailers can be custom printed similarly to boxes while avoiding UPS and FedEx DIM weight hang-ups. Plus, many options come pre-padded with bubble or paper to add an extra level of protection during the shipping process.

Printed Cartons OR Printed Tape

The growth in e-commerce sales has exploded the custom printed tape industry.

Higher minimums for printed cartons can sometimes get in the way of budgets and space. Consider instead printed water activated or packaging tape to get your box brand-ready. Another consideration? Low-volume case sealer is available at affordable prices to guarantee appropriate tape placement and predictable, consistent tape usage giving you better forecasting for shipping costs.

Custom Labels OR Printing on Demand

Marking and coding equipment has come a long way and the MPERIA series from Matthews allows for custom printed messages up to multi-inch height on demand by production line all maintained by one controller. Yes, one controller for a full plant of production lines and multiple printing needs (we are offering free demos now, just contact us). Custom labels are a great resource for consistent messaging but for co-packers or companies looking to change out messaging quickly the downtime of changing out partial rolls can be cumbersome, wasteful, and overall a bad deal.  Similarly, this can be a great option for companies that need to change dating, nutritional components, or other legally-driven information on the fly without wasting pre-printed labels.

EPS OR Hexacomb

More customers have approached us in recent years seeking a recyclable, compostable alternative to foam cushioning. Our answer has consistently been hexacomb. Hexacomb can be manufactured or scored on the floor to custom fit products being shipped. Similar to EPS, hexacomb can come with right-sized wells within the framework to create the best fit possible for products. EPS is still a top option and one we recommend often, but we recognize some companies are looking for a more sustainable-option to get them in line with their customer expectations and this is it.

Wooden Crates OR Ecorrcrates

Versatile, safe, and strong – ecorrcrates are a perfect substitute for heavy, cumbersome wooden crates.

We’ve talked about them before, and we’ll continue talking about them because they are just that great. Ditching the wooden crates has saved our customers time, resources, and potential workers’ comp claims. Forget the nails, tools and heavy lifting – plus your end user will be thanking you when they don’t waste valuable time opening and discarding the crate. Ecorrcrates are giving customers the durability they need without sacrificing shippablity domestically or internationally. Ecorrcrates can be custom made by shipment or modular for small-piece combined shipping. The possibilities are endless. We take your product to the design lab for maximum benefit. Plus. Ecorrcrates deliver flat and compact to you with easy set-up to save space before use. There is no losing when it comes to Ecorrcrates.

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Blown vs Cast Stretch Film

Stretch film comes in varying gauges, lengths, chemical make-ups, colors and can be used in numerous applications. Not all stretch film works on all loads and for all applications. One interesting variable and starting point for stretch films is deciding between blown or cast manufacturing processes. But first, if you are unsure of the differences between shrink and stretch start with this blog post.

Blown stretch film is created by blowing heated resin out vertically into a bubble. The bubble is then transformed into rolls while it is cooled by the surrounding air. This simple animation shows the basics of the process. Alternatively, another way stretch film is manufactured is by feeding a sheet of heated resin along a rolling path with chilled rollers while the cooling solidifies the film.  This process produces cast stretch film and like blown film is then turned into large master rolls. Check out this video showing the process.

Blown film is tougher and has less of a chance to puncture than cast. This occurs due to the slower cooling process, which allows the molecules in blown film to spread out as opposed to aligning in long lines like in cast. Blown film also has a higher level of cling (think Reynolds Wrap) than cast, making it stick to itself easier.

So, why would anyone use cast film? Cast stretch wrap has a clear, glossy finish allowing greater success with RFID and other scanning technology while blown film can be hazy and dull. Cast stretch film unwinds much quieter than blown. It is also easier to stretch and control the gauge with cast film.

Both films have great benefits for different applications.

Multiple variables can determine what film to use including the ones we talked about in this past blog post, but here are a few others when determining blown vs cast film:

  1. What type of machine is being used, if not applied by hand?
  2. What kind of load is being wrapped?
  3. Where does your skid go after leaving your dock? Is it temperature controlled?
  4. How is this skid transported and stored?
  5. How many variants of loads does your facility wrap?
  6. Do you use labels/barcodes under the film that need to be scanned?

Does your distributor ask you these types of questions and provide solutions based off of your answers?

If you are purchasing films based on the one with the cheapest price per roll, you may be surprised what kind of information and insight can be gained and the real savings you are missing out on. Our industrial packaging company represents several leaders in the market including Berry Plastics, Paragon Films, StretchTape, and Alliance Plastics with stock ranging from blown and cast hand and machine films, pre-stretch films, vented films, UVI, and specialty color films.

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Understanding Packaging Boxes and Corrugated Cartons

Understanding cartons can make or break your product – literally – by the time it gets to your customer’s door.  For instance, recycled corrugate is not created equally, and there are several ways to determine what kind of box you need besides the actual carton type.  Depending on the application companies can save money when it comes to changing the way their box is configured or even manufactured (for custom cartons).  Check out Colony Packaging & Machine’s top 4 points when looking into corrugated boxes.

Strength

The strength of a corrugated box starts with its material. A corrugated sheet consists of two major components – linerboard and medium. Linerboard is the flat paper that covers both sides of the sheet and the medium is the “fluted” or arched paper found between both liners. The flute, when anchored to the linerboards with a starched based adhesive, resists bending and pressure from all directions. When placed vertically on its ends, the flutes form vertical columns, capable of supporting considerable amounts of weight.

SingleWallCorrugated2
Single Wall Corrugated
DoubleWallCorrugated2
Double Wall Corrugated
TripleWallCorrugated
Triple Wall Corrugated

Material

The amount of virgin pulp fibers and the length of those fibers in a corrugated sheet substantially contribute to box strength. For example, the difference between a 200# test box and a 275# test box is that the latter has more pulp fibers in its corrugated linerboard. The 200# test box is rated to hold up to 65 lbs. of  contents while the 275# box can hold up to 95 lbs. A 350# test box is rated to hold up to 120 lbs. of contents.

Flute

Flutes come in five basic heights and shapes – the most common are “B-Flute”(used for die-cut boxes) and “C-Flute” (used for RSCs – regular slotted cartons and the most common of carton types). B-flute is compressed and appears thinner, but don’t be fooled. It is made with more paper to provide stronger side wall protection from blows and punctures during shipping.

C-flute is taller, with more air space, but offers enhanced stacking strength. For excellent graphic reproduction, consider E-flute because of its smooth surface and ability to hold up well during printing.

Flute Comparison

Measurements

Measure a box using the inner dimensions of an assembled box – Length (L) x Width (W) x Depth (D). Looking at an assembled box, the longer of the two sides is considered the length, the shorter of the two sides is the width, and the side perpendicular to the length and width is the depth of the box.

How to measure a box

The “Manufacturer’s Joint” is where the two ends of the side panels meet to form the box. At that point, the panels are fastened together with tape, staples (double or triple wall) or glue (single wall). This description applies to regular slotted shipping cartons (RSCs). The side panel thickness and content weight determine the type of seal used for the manufacturer’s joint.

Right-sizing your package is even easier nowadays with multiple, competitive options for custom and stock sized boxes.  We offer thousands of stock sizes and have relationships with several custom corrugated boxes manufacturers, which can decrease the amount of cartons you need to order – usually minimums start at 15 – 25 per size.  Browse cartons now!

Looking to take your cartons to the next level? Consider custom printing or custom printed tape to give your brand that wow factor when it hits doorsteps. Printing plates and die-cut charges don’t have to break the bank for mid-size and up companies. Not sure if your box usage would meet the minimum? Contact Colony Packaging and ask us. Quotes are free!

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New Partnership: LEIBINGER Continuous Inkjet Systems

We are excited to announce our new partnership with LEIBINGER Coding and Marking Systems. LEIBINGER helps fill the gap in our marking and coding equipment with their state of the art CIJ printer and printhead. If you know anything about CIJ you may have rolled your eyes at the “state-of-the-art” bit in that last sentence. But, we’ve got to tell you, they are seriously changing the game when it comes to their patented printhead.

LEIBINGER is within its third generation of family management and manufacturers all of its equipment from their headquarters in Germany. They are a ISO 9000 : 2015 certified company.

LEIBINGER caught our Service Manager’s eye a few years ago at the PackExpo in Chicago specifically for the maintenance dream their system offers. If you aren’t your company’s maintenance manager grab them now to read about some of these features that are changing the industry standard when it comes to CIJ printing, maintenance, and uptime.

  • “Sealtronic“, the automated nozzle seal in all LEIBINGER industrial inkjet printers, closes the nozzle and gutter airtight. This keeps the ink in the print head from drying out – the industrial inkjet printer is always ready to use. No time-consuming cleaning is required, even after long downtimes. During breaks in production, the gutter and the nozzle form an airtight circuit: No ink can leak out of the circuit and no air can get in. This keeps the ink fluid at all times – just like a sealed paint can – and the industrial inkjet printer is always ready to go.
  • Auto-Cycling – One of the worst parts about printing systems is always the headache dried ink causes in the lines. LEIBINGER’S CIJ has an automatic cycle feature which keeps the ink cycling through the lines once every 24 hours when not in use.
  • The large variety of interfaces allows you to integrate their units at any desired integration level – from simple data connection to complete full integration. And the compact print head with stainless steel housing also adapts seamlessly to your system – in any installation position, even for overhead applications.

We also have an entry-level unit on our floor ready for demo. We are factory-trained and ready to show off LEIBINGER’S full potential within your building.

LEIBINGER rounds out our full marking and coding options. We continue to work with Digital Design for TIJ (thermal inkjet), Matthews Marking and Loveshaw for DOD (drop on demand) and hi res. We also offer integration services through a third party for database-driven set-ups.

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5 Things to Consider When Buying Stretch Film

Understanding the difference between stretch film and shrink film is just the beginning to understanding stretch film’s capabilities in your production line.  Here are some points to discuss with your sales representative when determining the best film for your budget and application.

1. Determine the Load Size

Type A Loads: Uniform in shape. The load size closely matches the pallet size. These are obviously the easiest loads to wrap. Few film puncture points exist. This type of load is often seen at manufacturing locations where the same product is prepared for shipment load-after-load.

Type B Loads: Less uniform than type “A” loads. The stacking pattern may be irregular and /or the load size may not match the pallet size. Several film puncture points exist. More film selection judgement is required, especially at high levels of film stretch and /or high film application tension. Type “B” loads appear at smaller manufacturing locations and distribution warehouse locations. Each pallet contains two or three products palletized for a single destination.

Type C Loads: The worst of all to stretch wrap. No two loads are the same. Their size and shape range are all over the place. Sharp points seem to be everywhere and /or there is a major difference between the load and the pallet size. Film selection is critical. Type “C” loads are assembled at the distribution centers who supply retail store locations (i.e. grocery, drug, pet supply, automotive). Each load may contain dozens of different products.

stretch-film-load-types

2. Determine the Type of Equipment

Just as is true with any industry, the stretch film industry has gone through some huge changes when it comes to innovation in film manufacturing.  Because of these innovations, it is important to make sure your film matches the equipment being used to save on costs.

  • Spiral wrap film should generally be used when the loads vary in configuration.
  • Fully automatic high speed stretch wrappers equipped with pre-stretch usually require a premium grade of stretch film to make sure the equipment is being fully utilized.
  • Economy stretch films can be used for low stretch on conventional equipment.
  • A mid-range stretch film is needed for pre-stretch equipment operating at moderate levels.

For instance, if your piece of equipment can only pre-stretch your film 200% at most, you wouldn’t want to spend the extra amount on film that can stretch 400% because you aren’t benefitting from that added innovation.  Generally, the film that can stretch 400% is a premium film compared to the film that can only stretch 200% and you pay premium dollar for it.  Likewise, if your piece of equipment can pre-stretch your film up to 400% then you want a film that can meet that expectation without breaking – it will save you money per load in the long run.

3. Determine the Type of Product being Unitized

The weight of the pallet load and type of product being wrapped must be considered when selecting film type, gauge and number of wraps.  A significantly heavy pallet load will generally need a heavier gauge film than a very light pallet load.  For instance compare a pallet of cinder blocks and the impact of the weight of the load during the vibration that occurs in transit vs a pallet of pillows.  Although the loads might be the same L x W x H, different films might be necessary to secure the load efficiently at the lowest cost possible.

4. Determine Special Requirements

Some end users will have a need for a special requirement such as a one side cling, UVI or colored film. Reinforced film or vented film is also available. A one side cling is commonly used for bundling or on a pallet load that may shift in transit. Products that are stored outside for long periods of time normally require a UVI (Ultra-Violet Inhibitor) film. Heavy tinted colored films are often used to mask the product being wrapped for security reasons or for color-coding in large warehouses.

5. Determine Shipping Distance

The distance and method of shipment are important considerations. Films being transferred across the country in a flat bed truck or by rail would require a different film than a product shipped a short distance by truck or inter-plant.  Your warehouse set-up might ship both ways and could need two different films.  To help keep inventory on packaging products down it is important to discuss this when testing different films.

Contact Colony Packaging & Machine today to learn more.

 

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Bubble It!

Okay, we may not be starting the bubble wrap jacket craze (yet), but we are still crazy about bubble wrap. Bubble wrap has been getting a bad rep lately from companies talking big about environmentally-conscious packaging. But as an industrial packaging company, we are here to tell you bubble wrap is here to stay for good reason. Made-on-demand options, curbside recyclable features, historical success in packaging valuable products – air filled packaging is a tried and true method of getting your products safely to your customer the first time. Plus, it is easily reusable!

Made on Demand

Our top cushioning vendors like Sealed Air offer great bubble on-demand systems that allow companies to free up space on their floors with rolls of film in many configurations. That film takes up less trucking power also, cutting down on your company’s carbon footprint. Classic bubble wrap, pouches, tubes, pillows and more are all available for on-demand machines.

Curbside Recycling

Not all bubble wrap is recyclable, but we do offer options that are. Most lower grade bubble can be recycled with most other plastics. We offer several grades (strengths) of bubble in different bubble sizes that are curbside recyclable – ask us!

Tried and True

Did you know bubble wrap was actually invented because of a failed textured wallpaper attempt? It’s true! Many years later it is a fantastic option to get your product to your customer safely the first time which cuts down on returns and re-shipments.  Because of its lightweight and durable features it keeps the weight of your packages low while maintaining excellent cushioning.

Color Customization

We now offer custom colored bubble wrap and custom shapes through our made-on-demand options. Dog bones, hearts, stars, and more are all available to help customize your packaging for that perfect unboxing experience! We suggest adding your favorite hashtag to the inside of the box so your consumers know who to tag when they post their favorite packages!

This was just a quick run-down on the benefits of using bubble wrap. For more information on the bubble wrap options available to you contact your Sales Representative!