When is it time to switch packaging supplier?

Your packaging is the heartbeat of your dispatch line. It affects everything from production speed and shipping costs to the unboxing experience your customer receives. Yet, many businesses stick with a supplier that lets them down because they worry that switching will be a hassle.

We believe your packaging supplier should be a partner, not a problem. If you are constantly managing stockouts, chasing delivery updates, or paying to ship fresh air in oversized boxes, it’s time to look for a better solution.

At Manor Packaging, we support businesses across the East of England and the Midlands by delivering reliability, innovation, and peace of mind. Here are the clear signs that it’s time to switch, and how we can help you build a more efficient supply chain.

What Are the 10 Critical Signs Your Current Supplier is Failing You?

A reliable packaging supplier keeps your stock moving without interruption. You shouldn’t have to worry about where your next delivery is coming from. If you recognise any of the following operational problems, it indicates your current arrangement is holding you back:

• Late Deliveries: Shipments arrive after your slot, slowing down your production or dispatch teams.
• Inconsistent Quality: One batch is perfect, the next has misaligned print or a weak board, damaging your brand perception.
• Stockouts: They can’t fulfil your orders during peak periods, forcing you to ration packaging.
• Chasing Updates: You have to constantly chase them for order acknowledgements or delivery times (“Communication Darkness”).
• Poor Print Accuracy: Your branding colours vary noticeably between runs.
• Automation Failures: Boxes jam your case erectors or robotic packing lines because the manufacturing tolerances aren’t precise enough.
• Overuse of Void Fill: You are forced to buy excessive bubble wrap or paper just to fill gaps in oversized stock boxes.
• Low Pallet Efficiency: Poorly sized boxes reduce your pallet yield, increasing your shipping and storage costs.
• Damaged Deliveries: Packaging collapses under pallet weight or fails during transit, leading to product returns.
• High DIM Weight Charges: You are paying shipping costs for empty space because the boxes aren’t optimised for your product.
• Lack of EPR Data: They can’t provide the detailed weight and material data you need for your Extended Producer Responsibility reporting.

Why Is “Shipping Air” Costing You Money?

If you are using standard “stock” boxes, you are likely paying a triple penalty: higher shipping costs for sending empty space, higher material costs for void fill, and a higher carbon footprint.

We engineer packaging; we don’t just print boxes. Switching to bespoke corrugated packaging allows us to design and manufacture the box in-house to the exact dimensions of your product.

This doesn’t just save money, it improves your entire operation. Right-sized packaging improves pallet yield, reduces shipping costs, and boosts packing efficiency. Whether you are shipping fragile electronics or heavy industrial components, a tailored fit ensures your product is protected and your brand looks professional.

How Can You Ensure Your Packaging is Truly Sustainable?

Sustainability is no longer just a “nice to have”; it’s a business essential. 

We provide intelligent & sustainable corrugated packaging that supports your environmental goals. For businesses requiring audit-ready data, Manor Packaging delivers:

• Carbon-Neutral Manufacturing: The raw material for our board is produced at CorrBoard UK, where an on-site Anaerobic Digestion (AD) plant powers the corrugator providing renewable electricity and heat, making the board manufacturing process carbon neutral.
• 80% Recycled Content: Our board typically contains 80% recycled fibre, with the remaining 20% from sustainable certified forestry.
• 99.9% Recyclable Materials: All our corrugated output is fully recyclable at kerbside.
• FSC® Certified: We maintain a full FSC® Chain of Custody, ensuring complete traceability from the forest to the finished box.

See more about our sustainability page initiatives.

Why Does Vertical Integration Secure Your Supply Chain?

The structure of your supplier determines whether they can support you when the market gets tough.

Often  suppliers are “merchants” or middlemen who buy boxes from the open market, frequently switching supplier, offering no consistency. They rely on external box manufacturers and cannot guarantee availability. When paper demand spikes, they are often left at the back of the queue in a demanding marketplace.

Security of supply is business critical – The Manor Difference.

We operate differently. As part of the Fencor Packaging Group, we hold a part-ownership stake in CorrBoard UK, our principle sheet supplier. This vertical integration gives us priority access to corrugated board, even in the most difficult times. With Manor Packaging, this secures your supply chain from the paper reel to the finished box.

Additionally, the Fencor Packaging Group benefits from VPK Group’s minority shareholding, giving us direct access to one of Europe’s largest corrugated manufacturers if additional capacity is required. This means we are large enough to cope, but small enough to care.

What Makes Manor Packaging More Reliable Than Other Suppliers?

Reliability is measured by results. We consistently reinvest 6% of our sales turnover back into the business to ensure we have the latest technology and capacity to support your commercial growth, futureproofing your supply chain.

Here is why businesses across the Midlands and East Anglia trust us:

• Track record of 96–98.5% OTIF: We maintain a World-Class On Time In Full delivery performance. Your packaging arrives when you need it.
• 30% Capacity Headroom: We constantly plan for 30% rolling spare capacity. If you have a sudden spike in sales, we have the capacity and space to handle it.
• Manufacturing Scale: Our 61,598 sq ft manufacturing facility in Peterborough is equipped with industry-leading Bobst conversion equipment for precision and reliability.
• Stock & Serve: If your warehouse space is limited, we can help. Our 43,000 sq ft warehouse allows us to hold your stock and deliver Just-In-Time (JIT).
• Local Delivery Network: With our own fleet, we deliver daily across Cambridgeshire, Northamptonshire, Bedfordshire, Suffolk, and Hertfordshire.
• Certified Quality: We operate under ISO 14001 (Environmental) and ISO 9001:2015 (Quality) standards.

How Do We Make Switching Simple?

We understand that changing suppliers can feel daunting. That’s why our team works with you to manage the transition without disruption. We follow a proven, risk-free process:

1. Packaging Audit: We review your current range to identify where you can save money and improve efficiency, spotting the 5 common packaging mistakes costing you money.
2. Structural Design: Our experienced in-house design team uses CAD software and sample tables to engineer new designs quickly, focusing on pallet fit and automation compatibility.
3. Prototype and Testing: We produce physical samples for you to test on your packing line.
4. Transit Tests: We can help validate protection levels to ensure your goods arrive safely.
5. Stock Build: We manufacture your initial buffer stock before you stop ordering from your incumbent, ready to provide a JIT delivery service to ensure zero gap in supply.

Frequently Asked Questions (FAQs)

What are the risks of not switching a failing supplier?

Sticking with an unreliable supplier risks damage to your business and brand reputation, lost sales due to stockouts, and potential fines for non-compliance. Read more about the true cost of late packaging deliveries.

Does bespoke packaging cost more than stock boxes?

While the unit cost might look different on paper, the total cost of packing is often lower. Bespoke designs eliminate void fill costs, reduce shipping charges (DIM weight), and significantly lower your damage rates.

How do I know if a new supplier is reliable?

Look for measurable data. Check for OTIF performance statistics, proof of vertical integration (board supply ownership), and ISO certifications. You can use our guide to choosing a corrugated packaging supplier to help you decide.

Conclusion

It is time to switch your packaging supplier when your current partner ceases to perform and begins creating operational problems. Whether it is missed deliveries, rising damage rates, or a lack of proactive support, you shouldn’t have to settle for poor service.

Manor Packaging offers a secure, vertically integrated alternative. We combine carbon-neutral board manufacturing with precision engineering and a friendly, local service.

Take the Next Step

Don’t wait for a critical supply chain failure. Contact Manor Packaging today to book a free Packaging Audit. We’ll be pleased to help you analyse your current packaging and demonstrate exactly where we can help save you time, money, and carbon.