TVH

Macfarlane partnered with TVH UK following the acquisition of a glazing company, where a more efficient way to pack and ship fragile glass windscreens and components was required.

An initial consideration of a six-figure investment for machinery would have resulted in excess material waste, inefficient use of space and continued reliance on pallet-based distribution.

Macfarlane developed a streamlined alternative, using box optimisation software to reduce the packaging range to just four box sizes, covering over 350 glazing SKUs. Due to the project's success, this has now evolved with some changes to include an additional box, allowing the packaging range to cater for over 1000 SKUs.

Combined with Airsac inflatable packaging, this provided robust protection while enabling a shift from pallet shipments to courier delivery.

Macfarlane’s Innovation Lab also designed and implemented two compact packing lines, incorporating bespoke assembly frames, cushioned workstations, conveyors and in-line banding systems. The full solution was delivered within eight weeks.

This approach focused on improving efficiency and reducing cost across operations:

• Consolidated packaging across 350+ SKUs
• Enabled courier distribution, removing reliance on pallets
• Reduced material waste and surplus packaging
• Improved packing speeds and consistency
• Enhanced handling and reduced damages
• Avoided significant capital investment
• Delivered five-figure annual cost savings

The solution now supports shipping 200–250 units per week and provides a scalable model for broader European operations.

“I am very confident in stating that the project would have nowhere near achieved the level of success without the valuable input from Macfarlane Packaging"

Michael Walters, Warehouse Operations Manager at TVH UK

To find out more about TVH and their products or services, visit: https://www.tvh.com/