The Challenge: Reducing Costs While Maintaining Sustainability
A Hungarian manufacturer of plant-based finished products approached us with the goal of reducing their packaging costs. While cost-efficiency was a key focus, they also emphasized maintaining the security of pallet loads and minimizing environmental impact. With rising logistics expenses and the introduction of the EPR (Extended Producer Responsibility) fee, optimizing packaging had become a pressing issue.
Initial Situation
Prior to our collaboration, the company used 128 grams of stretch film per pallet. Although the load stability was satisfactory, both the film usage and the resulting costs and environmental footprint were ripe for optimization.
The Solution: Optimized Use of Super Power Film
The Manupackaging expert team conducted targeted testing and proposed a thinner but high-performance “super power” stretch film. This innovative material allowed for significant reduction in film usage without compromising load stability.
We also fine-tuned the machine settings to ensure that the new film would deliver the same secure wrapping results as before.
The Result: Measurable, Immediate Savings
Thanks to the new setup, the same pallet could now be securely wrapped using only 89 grams of film — a 30% reduction compared to the original amount. This improvement brought multiple benefits:
- 30% less plastic waste, significantly reducing environmental impact
- 30% reduction in EPR-related costs
- 25% savings on packaging costs per pallet
- Load stability remained fully intact, ensuring safe transport without compromise
Conclusion
This case clearly demonstrates that with the right technical expertise and packaging strategy, significant cost and material savings can be achieved without compromising product security. On top of that, environmental goals are also supported — reduced plastic usage, lower emissions, and minimized EPR contributions.
Would you like to optimize your packaging too? Contact us — we’re here to help you find the most efficient and sustainable solution!
Gábor Arató, Managing Director of Manupackaging Magyarország Kft.
