Case Study: Plastic to Paper
Client Overview
A leading consumer electronics and entertainment retailer in Australia, distributing popular products nationwide. Known for their commitment to quality and customer experience, the business recognised the importance of packaging not only for product protection but also for sustainability and brand presentation. With steady volumes moving through their distribution centre, finding a balance between efficiency, security, and environmental responsibility was key.
The Challenge
The client faced three interrelated challenges:
- Plastic Reduction
They needed to cut down on plastic usage in their shipping and packaging to meet sustainability goals and respond to both customer and stakeholder expectations for more eco-friendly solutions. - Security & Tamper Evidence
With high-value items being shipped, packaging had to be secure. The existing plastic tape could be peeled and resealed without visible damage, undermining confidence in transit security. - Branding Opportunity & Professional Appearance
Packaging is often the first physical touchpoint the customer has with the brand. The client wanted their parcels to look clean, premium, and aligned with their brand values. The plastic tape looked utilitarian and didn’t contribute much to the brand’s visual identity. - Efficiency and Cost Reality
Though eco-friendly solutions sometimes cost more upfront, there was a need to justify any change by showing gains in efficiency, reduced waste, or other cost savings over time. In the words of the client "The tape might cost more but we use less of it, we can do 43.5 packages with 300m of your tape, vs 14.5 packages with 300m of the plastic tape"
The Solution
Switch from traditional plastic pressure-sensitive tape to water-activated (kraft paper) tape, using dispensers to moisten adhesive and apply tape cleanly. Key features of the new solution:
- 100% recyclable kraft paper backing + starch-based adhesive
- Tamper-evident seal: once applied, any attempt to open the package leaves obvious evidence
- Custom printing or branded tape options to align with the retailer’s identity
- Dispensers installed in their distribution centre for consistent, clean application
Implementation
The transition was carried out in three clear stages:
- Trial in the Main Distribution Centre
A pilot program was run in the client’s main DC to measure real usage, performance, and staff workflow impact. - Staff Training
Packing staff were trained on the use of dispensers and proper sealing techniques to ensure consistent, professional application. - Full Roll-Out
After positive trial results and staff adoption, the switch was rolled out across all packing operations.