Automotive Parts Supplier Improves Protection and Reduces Packing Costs with Paper Cushioning

Automotive Parts Supplier Improves Protection and Reduces Packing Costs with Paper Cushioning

A UK automotive parts supplier has improved product protection, packing efficiency and packaging costs following the installation of two Protega Protect paper cushioning machines supplied by Severn Packaging.

The systems produce protective paper cushioning directly into mobile bins, which can then be wheeled between multiple packing benches. This gives the packing team a flexible supply of ready-to-use material wherever it is needed.

The Customer

The customer supplies automotive parts and components that vary considerably in size, weight and shape. Its packing operation therefore needs protective material that can be adapted to different products, carton sizes and levels of protection.

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

The Challenge

The previous packaging solution provided cushioning but was comparatively expensive. The business wanted to reduce packaging costs while maintaining—and where possible improving—the protection provided during handling, storage and transport.

Several packing benches are used across the operation, so the solution also needed to make cushioning readily available throughout the packing area without requiring a machine at every workstation.

The project focused on:

• Improving protection for varied automotive components.
• Reducing protective packaging costs.
• Supplying several packing benches efficiently.
• Adapting cushioning to different products and cartons.
• Reducing storage space for bulky pre-made packaging.
• Creating a simple and dependable operator workflow.

The Severn Packaging Solution

Following a review of the products, packaging requirements and warehouse layout, Severn Packaging installed two Protega Protect paper cushioning machines.

The systems convert compact paper packs into structured cushioning on demand. The finished material can wrap products, cushion vulnerable areas, fill empty space and help prevent components from moving inside the carton.

Central Production into Mobile Bins

Rather than locating a machine at every bench, the two systems produce material directly into wheeled storage bins. Filled bins can be moved to whichever packing benches need cushioning, while empty bins return to the machines for replenishment.

This creates a straightforward circulation system that keeps material available across the operation while making efficient use of the equipment.

Capacity and Resilience from Two Machines

The two-machine arrangement provides enough capacity to prepare material for several workstations and maintain availability during busy periods. It also gives the operation greater resilience because cushioning production is not dependent on one system.

Protection Matched to Each Product

Packers can select the amount and arrangement of cushioning according to the component being dispatched. This is especially useful for automotive products with different dimensions, weights and vulnerable surfaces.

Compact Material Storage

The paper is held in compact packs before being converted into high-volume cushioning. This reduces the storage space required for bulky protective packaging and allows material to be produced in the quantities needed.

The Results

Improved Product Protection

The structured paper cushioning helps absorb impacts, restrict movement and separate parts inside the carton, improving protection throughout handling and distribution.

A More Cost-Effective Solution

The new system provides a more cost-effective alternative to the customer’s previous protective packaging while delivering the performance required for demanding automotive components.

Flexible Supply to Multiple Benches

Mobile bins allow cushioning to be positioned wherever demand is greatest. The customer gains the efficiency of centralised production without restricting packers to fixed workstations.

Material Available When Required

The team can prepare cushioning in volume and replenish bins throughout the working day, helping prevent shortages at the benches during busy periods.

Reduced Storage Requirements

Producing cushioning on demand from compact paper packs reduces the space needed to store bulky protective packaging.

Key Project Benefits

• Two Protega Protect paper cushioning machines installed.
• Improved protection for varied automotive parts.
• Lower costs than the previous packaging solution.
• Cushioning produced directly into mobile bins.
• Material moved easily between multiple packing benches.
• Central production without a machine at every workstation.
• Flexible wrapping, cushioning and void-fill applications.
• Capacity and resilience from a two-machine setup.
• Compact material storage before conversion.
• A straightforward replenishment process for operators.

Customer Comment

“The mobile-bin arrangement works particularly well for our operation. We can produce cushioning in volume and move it directly to whichever packing benches need it. The new systems give our components excellent protection and provide a more cost-effective solution than the packaging we were previously using.”

Warehouse Manager
Automotive Parts Supplier

Severn Packaging Comment

“This project shows how centralised paper cushioning production can support several packing stations without requiring a machine at every bench. By installing two Protega Protect systems and producing material into mobile bins, the customer has improved protection, reduced packaging costs and created a flexible supply of cushioning that fits its existing workflow.”

Lee Williams
Sales Director, Severn Packaging

Paper Cushioning Designed Around the Packing Operation

Severn Packaging supplies paper cushioning systems for individual packing benches and multi-station warehouse operations. Each solution can be configured around the products being packed, the required level of protection and the way protective material needs to move through the packing area.