Case Studies
Case Study: Reusable Stillage sides
Client: Multinational Furniture Manufacturer
Region: UK, Europe, USA
Solution by: Palband – Reusable Solutions for Reliable Logistics
Overview
Large metal stillages are used by this multinational furniture company to transport flat packed furniture across the UK, Europe and the USA and these were always wrapped in large amounts of plastic shrink wrap which amounted to a huge amount of plastic waste. We designed a strong and durable reusable stillage side with metal components to ensure the products were kept free from any damage.
Another issue that was resolved was the inconsistency of the shrink wrap application which often resulted in heavy furniture boxes coming lose during transport and causing irreparable damage.
- 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 designed and delivered a custom reusable stillage side system, developed specifically for the unique challenges of flat-packed furniture logistics.
- Durability First: Each unit features robust construction, with integrated metal reinforcement to withstand repeated use and protect contents during long-haul transportation.
- Secure and Reliable Fit: The reusable sides ensure consistent load containment—no variation in application, no risk of under-securing. This dramatically reduced movement during transit and virtually eliminated damage caused by shifting loads.
- Sustainability Impact: By removing the need for shrink wrap, the company cut down on hundreds of tonnes of plastic waste annually—supporting their ESG goals and improving their environmental footprint.
The Results
- Plastic waste reduced by over 90% on stillage-wrapped shipments
- Significant reduction in product damage, with a notable drop in customer complaints and returns
- Improved efficiency during loading and unloading, thanks to the simplicity and uniformity of the reusable system
- ROI achieved within the first 12 months, with long-term savings projected across all operational regions
“Palband’s reusable stillage sides have helped us cut plastic waste and reduce product damage during transport. A simple, effective solution that’s made a big difference.”
Logistics Manager, Multinational Furniture Company
