Macfarlane, Lancaster University launch packaging minimiser software

UNITED KINGDOM – Macfarlane Packaging and Lancaster University have created software intended to cut packaging overuse, and funded through a UK Government applied research collaborations grant.

The software forms the basis of a Packaging Minimiser service available only to Macfarlane customers. An algorithm examines shipments to identify unused space, excessive packaging and instances where unsuitable materials are being used. 

Macfarlane can then propose alternative packaging arrangements aimed at reducing costs, material use and carbon emissions. 

The system is intended to reduce the time needed for assessments and improve their accuracy, addressing a longstanding bottleneck in packaging optimisation where manual audits limit how frequently specifications can be reviewed.

Testing Records 15 Percent Average Material Reduction

Testing by Macfarlane’s Innovation Labs found that the service reduced packaging material use by an average of 15 percent, as well as reducing unused space and costs. 

The software can lower parcel weights and transport-related carbon emissions, reduce the number of packaging products required and make packaging easier to store. 

It is designed to support compliance with UK and EU packaging waste rules, including Extended Producer Responsibility and the Packaging and Packaging Waste Regulation, and reduce total packaging costs.

Service Targets High-Volume and Complex Shipping Operations

The service is intended for manufacturers, distributors, third-party logistics companies and retailers managing large volumes of products with varied and complex packaging requirements. 

Rachel Fellows, national accounts sales director at Macfarlane Packaging, said the tool was a gamechanger for customers shipping at scale. 

She added that with the new Packaging Minimiser, the company could assess needs in days rather than weeks, saving money, cutting carbon emissions and helping customers stay compliant with every relevant regulation.

University Team Led Software Development

Jamie Fairbrother, an operational research lecturer at Lancaster University, led the software’s development team. 

He said the software optimised packaging options for dispatching orders, helping businesses reduce packaging and courier costs while benefiting the environment. 

He added that Macfarlane Packaging’s expertise in the field would enable the company to maximise those benefits for customers. 

Earlier this year, Macfarlane Packaging introduced the PadPak Guardian 30, a paper cushioning system developed by Ranpak, designed for organisations dispatching more than 50 packages daily and compatible with Kraft, recycled Kraft and Ecoline papers. 

The software launch extends Macfarlane’s focus on combining digital assessment tools with physical packaging systems to address material reduction across the fulfilment chain.

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