Case Studies

How MorsaPack found the most efficient packaging solution for a 3PL supplier

Prioritising pallet stability helped our client in the e-commerce and logistics sector to lower packaging costs, pallet weights and packaging processing times.

Client: Global contracts logistics supplier – offering outsourced supply chain and warehouse management

Service overview:

Finding the right pallet wrap delivers financial, operational and environmental efficiencies. 

The client wanted to check that their packaging solution was delivering both the required level of pallet stability for transporting paint, as well as maximum cost and resource efficiency. Our testing found that using a thicker film delivered the optimal holding force without adding excess packaging weight or cost per wrap.

Efficiency in the client’s packaging operations is essential as they deliver logistics services to the e-commerce, distribution and warehousing sectors.

Results from pallet stability testing and packaging cost audit conducted by MorsaPack

  • £95,000 annual saving
  • 29% cost reduction, per pallet
  • 33% weight reduction, per pallet – 28 tonnes of packaging removed every year
  • 35% increase in capacity

Client request:

The client wanted to find whether the stability, or containment force, required for the products could be achieved using different thicknesses or volumes of films.

Earlier manual testing suggested savings of up to 15% could be achieved by using a thinner film (15mu). The client was keen to ensure this testing had delivered accurate results before changing the specification of film used.

The client is trusted to manage the storage, packaging and transportation of paint on behalf of their client – a potentially hazardous, and costly, task if not delivered correctly.


Applying the right thickness and volume of film to pallets is essential to ensure reliable pallet stability. Too little film will compromise the security and integrity of loads, risking items being dislodged or damaged during transit. Too much film will add unnecessary packaging weight, creating extra costs, excess waste and adding to emissions during transportation.

MorsaPack’s approach:

We tested the containment forces achieved by the film as applied to pallets, changing the thickness and wrap pattern of film used to find the most effective combination and configuration. This included testing different thicknesses, stretches, tensions and number of revolutions of film – at 15mu and 20mu.

Reference is W9 20mu with half the number of revolutions as current 15mu

Using our pallet stability testing and working to EUMOS testing protocols, the containment force was measured. This testing method creates a benchmark to work to and can identify any potential weak points in the wrapping result.

Additionally, using an automated testing method prevented human error or changeable factors from skewing the results.

Prior to testing, the client was achieving the required stability by using 302g of 15mu film at 36 revolutions, costing £0.914 per wrap.

By testing a range of options, we found that applying a 20mu film at 18 revolutions delivered the same stability at just 202g and costing £0.645 per wrap. Across the huge volume of paint being packaged and transported, this saved the client c.£95,000 annually.

Client feedback:

“We were extremely impressed with the openness that Robert from MorsaPack approached this with. Every attempt was made to include us in the process so that we understood the full facts about the film, how it worked and what the results were.

“Now we are confident that we are getting the same stability which is extremely important to what we do and are now making the savings in costs as well as packaging used.

“The most critical things for us in choosing a pallet wrapping supplier is that they have an interest in giving us the know-how and the confidence that when we despatch a pallet we know it will get to its destination without loss or damage. Now we know that we have a stable pallet at a lower cost and using less packaging. Win, Win and Win.”

MorsaPack’s view:

Robert McEwan, Managing Director of MorsaPack, said: “The key thing for this application was to ensure that there was no reduction in containment force to the pallet. To be sure of this you need to remove the human element in the tests so that the containment force is measured accurately. With this product (paint) you need the stability created without applying too much tension as some products may crush and burst the lids.

“We are always happy to be able to share our expertise and knowledge with our clients so that they can be more confident in the safety of their shipments.”

Working to EUMOS standards for load stability

The European Safe Logistics Association (EUMOS) sets the safety standards for the testing, loading and securing of palletised goods being moved by road, rail or freight. 

Its protocols – namely EUMOS 40509 – ensure the rigidity and safety of loads during transportation.

Our service here applied the principles and protocols of EUMOS 40509 to ensure safety standards are met.

Need to find an efficient packaging solution for e-commerce goods? Contact our team today.

Read our articles on pallet stability.

© MorsaPack Packaging All Rights Reserved