Lighting Manufacturer Achieves Zero-Plastic Warehouse with Palband Wraps
Case Study: Furniture Manufacturer Reduces Plastic Waste with Reusable Stillage Wraps
Client: Mike Napthine
Region: UK, Europe, USA
Solution by: Palband – Reusable Solutions for Reliable Logistics
Overview
A leading lighting manufacturer set an ambitious sustainability target: to remove all single-use plastic from its production and warehousing operations. The CEO wanted to demonstrate that efficiency and environmental responsibility could work hand in hand, replacing disposable materials with long-life, reusable alternatives.
Palband was invited to design a reusable wrapping system for their stillages, which varied in size and use across the facility. After an on-site assessment, we created a suite of colour-coded wraps that matched each stillage size and included purpose-built fittings for a precise, secure connection to every frame.
- Excessive Plastic Waste: The sheer volume of shrink wrap used on every stillage—across thousands of deliveries—generated a significant amount of single-use plastic waste. This clashed with the company’s growing focus on sustainability and their commitment to reducing environmental impact.
- Inconsistent Application: Shrink wrap was often applied unevenly across sites and by different teams, leading to unpredictable levels of security.
- Product Damage: Inadequate or loose wrapping occasionally allowed heavy boxes to shift during transport. This led to goods arriving damaged or, in some cases, completely unsellable—impacting both customer satisfaction and financial performance.
Our Solution
The transformation was immediate. What had once been a warehouse cluttered with half-wrapped stillages and loose layers of shrink wrap became a clean, organised space with a consistent, professional appearance. The new Stillage Wraps and Sides provided full containment for lighting components, preventing items from slipping or becoming damaged, while delivering a major reduction in single-use plastic waste.
“Our colour-coded design made it easy for staff to identify and secure each stillage quickly, creating a smoother process and a smarter workspace”, said Mike Napthine, Client Solutions Lead at Palband. “The improvement in presentation and efficiency was clear from the first day of use.”
The success of this project has encouraged the manufacturer to expand its sustainability programme, with further plastic reduction initiatives already underway across packaging and shipping processes.
The Results
- Sharp reduction in single-use plastic across production and warehousing
- Improved organisation with colour-coded, size-matched wraps
- Enhanced safety and protection for stored and in-progress components
- Stronger alignment with corporate sustainability and ESG goals
- Positive internal feedback on usability and workspace presentation
“The result was a smarter, safer, and far more sustainable operation – proof that practical design can drive real environmental progress”
Mike Napthine, Client Solutions Lead, Palband.
