Category: Case Study

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!”

Palband produced a range of custom insulated waterproof covers designed specifically for the company’s IBCs. Built from durable, weather-resistant materials, the covers included high-performance insulation to prevent freezing, even in prolonged low temperatures. To make daily use simple, we integrated flap openings into each design, allowing the IBCs to be emptied without removing the covers.

Each unit was finished in the company’s branding, providing a professional look alongside dependable thermal protection. The result was a robust, reusable system that delivered long-term performance and immediate peace of mind.

“Our insulated IBC covers allow clients to store liquids outdoors in any weather without concern,” said Mike Napthine, Client Solutions Lead at Palband. “They protect contents effectively while maintaining accessibility and a consistent, branded appearance.”

Palband supplied a set of custom Heavy-Duty Pallet Covers built from UV-stabilised, waterproof PVC580 fabric. Each cover was tailored to the client’s container dimensions, ensuring a snug fit and consistent protection against rain, dust, and debris.

The design included Velcro-opening sides for quick access, document wallets for identification, and branding in the client’s corporate colours and logo. The covers provided an immediate improvement, containers could now be stored outdoors in all weather without water ingress, eliminating drying time and reducing handling delays.

“Our aim was to remove the hassle completely,” said Mike Napthine, Client Solutions Lead at Palband. “The covers protect the containers year-round and present a clean, professional look every time they’re used.”

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.

Palband designed a closed-loop system based on its Reusable Pallet Wraps. Each wrap was built to the client’s exact pallet dimensions, with robust fastenings that maintain load stability during movement between the warehouse’s six mezzanine levels.

The wraps are used for internal transfers only, goods are wrapped on the ground floor, transported to upper levels, unwrapped, and then the wraps are returned downstairs for immediate reuse. This efficient cycle saves time, cuts out thousands of metres of single-use film, and ensures consistent handling across shifts.

“Our goal was to simplify their internal logistics while delivering a measurable environmental impact,” said Mike Napthine, Client Solutions Lead at Palband. “Reusable pallet wraps have achieved both, reducing plastic waste and improving operational flow.”

Palband developed a set of fully customised Insulated Roll Cage Covers tailored precisely to the retailer’s cage sizes and operating requirements. Each cover features a multi-layer construction with thermal insulation, a durable waterproof outer surface, and a reflective silver foil inner lining to maintain temperature consistency throughout the cold chain. The thickness of insulation was calculated to extend the safe transit window beyond the required time, providing full assurance that any short delay would not compromise food quality.

To align with the retailer’s distinctive visual identity, we branded every cover with their logo and colour palette, ensuring a professional, consistent look across all locations. The final product combined function, durability, and presentation, delivering a premium reusable solution that supported both operational and environmental objectives.

Palband designed a reusable pallet wrapping system built around our Reusable Pallet Wraps. Each wrap was tailored to the bakery’s pallet dimensions and typical tote heights, with a simple fastening layout so crews could secure a load in a single walk-round rather than the twenty laps required with plastic film. Options for colour coding and clear document wallets supported rapid identification and batch control during busy production windows, while durable materials ensured the wraps stood up to constant daily handling and frequent changeovers between proving and bake-off.

“We set out to make the right method the easiest method,” said Mike Napthine, Client Solutions Lead at Palband. “If a wrap goes on in seconds, stays secure in motion, and comes off just as quickly at the oven, teams keep using it day after day.”

Palband worked closely with the client to replace the outdated system with a durable, reusable stillage side solution, built specifically for their frame designs and logistics routes. Using our Stillage Wraps and Sides, we created a system that prioritised safety, consistency and long-term sustainability.

Each wrap was engineered from robust materials and reinforced for daily use in a busy warehouse environment. Secure, uniform fastenings ensured every stillage was safely contained with no variation in application, while the design allowed easy access for loading, unloading and inspection. The result was a neater, faster process that eliminated the frustration of uneven shrink wrapping and the waste it produced.

“Our goal was to design something that solved several problems at once – improving safety, reducing waste, and speeding up the process,” said Mike Napthine, Client Solutions Lead at Palband. “By looking closely at how the stillages were used day to day, we could create a system that genuinely made a difference.”

By removing shrink wrap from their operation entirely, the manufacturer not only improved handling efficiency but also cut down on hundreds of tonnes of plastic waste each year. The change supported their wider ESG goals and demonstrated a practical, scalable step toward a more sustainable logistics model.