Leading UK Clothing Supplier Reduces Packaging Costs and Lead Times with Fan-Folded Mail Bags

Leading UK Clothing Supplier Reduces Packaging Costs and Lead Times with Fan-Folded Mail Bags

A leading UK specialist clothing supplier reduced packaging costs, improved sustainability and strengthened supply security by switching its fan-folded mail bags and print consumables to Severn Packaging.

The Customer

The customer is a leading UK specialist clothing supplier operating a high-volume e-commerce fulfilment operation. Its packing team processes significant order volumes, with particularly demanding seasonal peaks when packaging availability and machine performance are critical.

The company has not been named in this case study at its request.

The Challenge

The customer was using an established automated e-commerce packaging machine and sourcing its fan-folded mail bags directly from the existing equipment supplier.

Although this provided a single source for the machinery and materials, the bags were comparatively expensive and manufactured overseas, creating long lead times and limiting the customer’s ability to respond quickly when demand increased.

The customer was understandably cautious about introducing an alternative material. Any new bags needed to run reliably through the existing machine without affecting packing speed, sealing performance or day-to-day productivity.

The project focused on:

• Reducing the cost of fan-folded mail bags.
• Demonstrating compatibility with the existing machine.
• Maintaining or improving packaging performance.
• Improving the sustainability credentials of the bags.
• Reducing reliance on long overseas lead times.
• Providing dependable stock availability during seasonal peaks.
• Simplifying the supply of bags and print consumables.

The Severn Packaging Solution

Severn Packaging reviewed the application and supplied fan-folded mail bags for testing on the customer’s automated e-commerce packaging machine.

The trials clearly demonstrated that the Severn Packaging bags ran effectively through the existing equipment, providing dependable feeding, printing and sealing performance. This gave the customer confidence that it could change material supplier without replacing or modifying its machinery.

Improved Commercial Value

The new bags provided a more cost-effective alternative to those supplied through the original equipment provider. This allowed the customer to reduce packaging costs without compromising machine performance or finished-pack quality.

Improved Sustainability Credentials

The Severn Packaging specification also provided improved sustainability credentials compared with the previous material, helping the business reduce the environmental impact of its e-commerce packaging operation.

Dedicated Stock Holding

To address the long lead times associated with overseas manufacturing, Severn Packaging established a dedicated stock-holding arrangement.

Agreed quantities are held specifically for the customer and can be called off with delivery in as little as one working day. This provides much greater flexibility during busy periods and reduces the risk of packaging shortages affecting order fulfilment.

A Complete Consumables Supply

Following the successful switch to Severn Packaging’s fan-folded mail bags, the customer also transferred its printer ribbons and replacement printheads.

The business now sources its packaging materials and print consumables from Severn Packaging, creating one responsive UK point of contact for ongoing supply and technical support.

The Results

Reduced Packaging Costs

Changing supplier delivered a more competitive bag price while maintaining reliable performance through the existing e-commerce packaging machine.

Proven Machine Compatibility

Testing demonstrated that the bags fed, printed and sealed effectively, giving the customer confidence to move away from the machine supplier’s material supply.

Shorter, More Dependable Lead Times

Dedicated UK stock holding replaced the uncertainty of long overseas manufacturing lead times. Stock can now be delivered in as little as one working day when required.

Greater Flexibility During Peak Periods

The call-off arrangement helps the customer respond to changes in order volumes without holding excessive packaging stock at its own premises.

Improved Sustainability

The revised bag specification provides stronger sustainability credentials, supporting the customer’s wider environmental objectives.

One Supplier for Materials and Consumables

Fan-folded mail bags, printer ribbons and replacement printheads are now supplied by Severn Packaging, simplifying procurement and providing one point of contact for the complete application.

Key Project Benefits

• Reduced fan-folded mail bag costs.
• Proven performance on the customer’s existing machine.
• Improved sustainability credentials.
• Dedicated customer stock holding.
• Delivery available in as little as one working day.
• Reduced exposure to long overseas lead times.
• Greater supply security during seasonal peaks.
• Printer ribbons supplied by Severn Packaging.
• Replacement printheads supplied by Severn Packaging.
• One responsive UK supplier for materials and consumables.

Customer Comment

“We were initially cautious about moving away from the material supplied with our packaging machine because the existing arrangement was familiar and everything came from one source. Severn Packaging took the time to test and demonstrate the bags properly, and they have performed extremely well. The pricing, sustainability credentials and stock-holding arrangement are all significant improvements. Having bags, ribbons and replacement printheads supplied through one responsive partner has also made the whole process much easier to manage.”

Operations Manager
Leading UK Specialist Clothing Supplier

Severn Packaging Comment

“The customer did not need to replace a successful packaging machine—it simply needed a more competitive and responsive supply arrangement around it. By proving our fan-folded mail bags on the existing system, we removed the risk associated with changing supplier. The customer now benefits from improved material costs, stronger sustainability credentials and dedicated UK stock that can be delivered in as little as one working day. Adding ribbons and replacement printheads means we can now support the complete materials and consumables requirement.”

Lee Williams
Sales Director, Severn Packaging

A More Flexible Supply Solution for Existing E-Commerce Machines

Severn Packaging supplies fan-folded mail bags, printer ribbons and replacement printheads for a wide range of automated e-commerce packaging systems.

Through material testing, dedicated stock holding and responsive UK delivery, businesses can reduce packaging costs and improve supply security without being tied to the original equipment manufacturer for ongoing consumables.