Reusable Pallet Wraps Help Electrical Supplier Eliminate Single-Use Plastic
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 national electrical parts supplier needed a reusable pallet wrapping system to serve a blue-chip communications customer that had introduced a strict zero-plastic policy for inbound deliveries. Weekly shipments were still reliant on single-use pallet wrap, which conflicted with the customer’s requirements and created waste, inconsistency, and unnecessary handling time. The supplier asked Palband to help design a practical alternative that would secure varied load types, include a waterproof lid, and present a professional, branded appearance that would not be mislaid in a busy goods-in environment.
After an initial consultation, we mapped the supplier’s pallet sizes, common load profiles, and delivery rhythm for the contract. Trials followed at depot and on route so the team could test fastenings, loading access, and document handling in real conditions. Working iteratively, we refined the design and introduced clear ownership labelling, with company logo and consignment information visible on every face to reduce loss and speed identification at the customer’s receiving bays.
- 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
Palband delivered a tailored system built around our Reusable Pallet Wraps. The wraps use tough, coated mesh for strength without excess weight, with adjustable sections to suit mixed carton heights and a waterproof lid to protect sensitive components in poor weather. Colour coding supports quick segregation by route, while integrated document wallets keep delivery notes secure and visible. The fastening layout is simple and consistent, so pallets can be secured in seconds and released just as quickly at goods-in, ready for back-haul and reuse.
“From the outset, we focused on a design crews would choose to use,” said Mike Napthine, Client Solutions Lead at Palband. “Fast, repeatable, and clearly branded, so it meets the contract spec and makes everyone’s job easier.”
The operations manager overseeing the change told us: “Palband were absolutely instrumental in us achieving our complete removal of single use plastic pallet wrap from our weekly deliveries to a major contract customer. They worked with us to design a bespoke product fitting our exact needs over the course of several consultations, with several prototype and field tests. Our customer was very impressed with the final product and it has recommended it to other suppliers into their stores. Palband’s responsiveness, professionalism and a patience we probably didn’t deserve was very much appreciated and I would not hesitate to recommend anyone looking to reduce their SUP footprint to work with them; you absolutely will not be disappointed!”
The Results
- Single-use plastic pallet wrap eliminated on contract deliveries
- Consistent, secure presentation with branded, trackable wraps and waterproof lids
- Faster loading and release at goods-in due to simple, repeatable fastening
- Positive customer feedback and supplier-to-supplier recommendations within the network
“Our customer’s response has been outstanding,” said Mike Napthine, Client Solutions Lead at Palband. “This project shows what can be achieved when sustainability targets are matched with practical design. The wraps not only helped remove single-use plastic completely but also improved efficiency and presentation across every delivery.”
Mike Napthine, Client Solutions Lead, Palband.
