There is a slow, but significant shift in parcel packaging occurring. More efficient ways to package goods are being explored and more eco-friendly packaging materials are being used. Alternatives to poly mailers, such as recyclable cardboard and biodegradable plastics, are being experimented with.
In addition, smaller, more customized packaging is helping companies take advantage of dimensional weight pricing that results in reduced shipping costs. These changes are affecting how parcels are processed through automated parcel sorting systems.
The “poly” in poly mailers refers to polyethylene. This is a petroleum-based plastic that takes hundreds of years to break down in the natural environment. When discarded, these bags end up in landfills, but also make their way into rivers and oceans where they pose a threat to wildlife and leech chemicals into the ground and water. Although some plastic packaging can be recycled, it often is not.
Plant based mailers are one alternative that is being experimented with. They are fully compostable and made from materials like cornstarch, polybutylene adipate terephthalate (PAT) and cassava. PAT is a plastic made from biodegradable materials such as adipic acid, butanediol, and terephthalic acid. Cassava is a root vegetable found in sub-tropical regions such as South America.
Paper mailers made of kraft paper are another option that is gaining popularity as an alternative to plastic. Kraft paper is made of wood pulp and is known for its relative durability. And it is fully biodegradable. Additionally, many paper mailers are made using recycled material.
Although not as environmentally friendly as compostable plastic alternatives, recycled poly mailers are also being used more in an effort to help reduce new plastic production.
Amazon is the most high-profile organization that is currently experimenting with biodegradable mailers. In addition to their efforts to reduce poly-based envelopes they are also phasing out plastic air pillows that are being replaced with paper fillers. And they are encouraging customers to receive items in their original packaging.
Several other plastic alternatives are being experimented with including mushroom and seaweed based packaging and cushioning materials.
In an effort to minimize waste, reduce the amount of fill required to pad voids inside boxes, and take advantage of dimensional weight shipping costs, organizations are exploring customized boxes.
Right-sizing packaging through customization allows the product to fit perfectly inside the box with limited wasted space. This not only helps reduce the amount of overall material being used, but also reduces the amount of filler required, such as plastic bubble wrap, peanuts or paper fillers. The tighter fit of custom packaging also helps secure the product from movement during shipping.
Organizations are also looking at the optimal thickness of the cardboard they are using. By optimizing material thickness, companies can potentially use thinner, and thus less, material.
As with any new product, biodegradable shipping bags are being faced with a few challenges. One of them is how they perform when processed through automated parcel sorting systems.
Biodegradable bags typically have a more porous, less smooth texture. Labels that work with traditional poly bags may not adhere as well to this type of surface. As a result, labels need to be sourced that use adhesives compatible to biodegradable substrates. Label material is also a consideration, as traditional adhesives themselves are not typically biodegradable. Fully biodegradable labels are becoming more popular as a result.
Environmentally friendly poly bag alternatives tend to become more easily wrinkled. This can pose issues with barcode scanners as labels can become warped. The barcode reader settings may require adjustment and/or higher quality labels may be required that are less prone to wrinkling.
Durability is also an issue. One of the main benefits of the poly bag is its ability to hold up during traditional processing and shipping. When biodegradable bags are run through an automated parcel sorting system, their more fragile nature makes them prone to damage. Specific conveyors, automatic labelers, dimensioning systems, and sorters may need to be used that handle the parcel more gently.
Organizations that are considering changing packaging types will likely need to look closely at their existing sorting technologies, and other features of the system, as they apply to handling these new materials. New sorters, automatic labelers, and scanners may be required. Those that are entering the automated parcel sorting system market will want to consider the packaging types as they choose the features that will be included during the design and build phase of new systems.
Besides reducing the overall quantity of material being used per shipment, custom packaging can lead to reduced shipping costs. Carriers charge per piece using dimensional weight in addition to actual weight. Dimensional weight is based on the overall height, width and length of the parcel. Smaller packaging designed to fit the product more precisely can reduce the dimensional weight, and therefore reduce the cost to ship each product.
Changes in packaging, and how they affect automated parcel sorting systems, are constantly evolving. New materials are being rolled out and tested ongoing, and alternative methods of managing the new materials are somewhat fluid. It does appear, however, that these changes will eventually become the norm. As a result, operations that package goods for shipment should keep an eye out on evolving technologies and materials.
