A leader in sustainable packaging
"Loughborough-based packaging specialist Colton Packaging is committed to sustainable best practices. Beyond investing in operational measures that reduce the firm’s environmental impact, Colton is focused on being a market leader in reducing its clients’ carbon footprint.
It sources its corrugated cardboard packaging from FSC-registered manufacturers in the UK and, by choosing a recyclable material, Colton helps businesses meet their environmental targets. With an experienced in-house design team, each client’s packaging needs are met with a bespoke, innovative approach that delivers sustainable results.
Creating a 100% recyclable packaging solution
In 2022, two of its manufacturing clients wanted to improve sustainability and reduce waste, so Colton’s team drew from more than 20 years’ experience, to reimagine the polystyrene corner pieces used to protect doors and frames, to find a sustainable alternative.
• Reimagining plastic corners Using the original packaging parts as a template, the team visualised the pieces as flat-scored, corrugated sheets, designing bespoke recyclable corrugated cardboard inserts. The final designs were flat pack to store and easily folded into 3D protective corners that slot on doors and window frames. For various product thicknesses, an additional insert was created to prevent movement during delivery and transportation. Different versions with protective buffers were also created to accommodate protruding sections.
• 100% recyclable solution The solution has 100% replaced polystyrene and delivered multiple practical and carbon-saving benefits without compromising quality. The clients are seeing a 30% materials cost reduction and, as the new design takes up less than 25% space than before, lorry deliveries are reduced, minimising mileage and fuel consumption. The benefits are also being multiplied across the end users; on building sites where the doors and frames are received, developers can achieve zero waste to landfill and improve recycling from packaging.
Developing recyclable storage solutions ¬¬¬¬¬In early 2023, Colton’s online fulfilment client wanted to reduce overheads and become more sustainable by switching its plastic bin totes to a newly-designed and environmentally-friendly alternative.
• Made to measure solutions Following a visit to the warehouse facility to measure up for the new totes, the client shared plans to create more picking locations with a greener alternative to expensive plastic trays, meaning the design needed to be scalable. Colton’s designers created made-to-measure corrugated cardboard bin totes that were large enough yet structurally strong enough to handle the constant demands of a busy warehouse, without compromising on quality.
• Speedy service The team designed, sampled and delivered the corrugated cardboard alternative within three weeks, and the client has been so impressed, it has been rolled out across its warehouse operations. While the totes were made to fit a large bay, they can also be reproduced in alternative sizes, and the design team has already developed and produced half-bin totes for smaller goods.
• Scalable sustainability While making picking easier and creating shorter lead times, the design can now be supplied flat, taking up less space in the warehouse. The client has an innovative, greener, 100% recyclable alternative to plastic that can be scaled up or down as required."