Most 3PL and ecommerce businesses plan well ahead for peak season. But Black Friday and Christmas logistics rarely go exactly to plan.ย ย
Effective peak season packaging preparation also means knowing how to respond when the original plan needs adjusting. This is where a responsive packaging partner helps prevent disruption. At Lesters Packaging, continued investment in our facilities, equipment and capacity is designed to make that response faster.ย ย ย
Hereโs how to spot problems early and keep orders moving during Black Friday and Christmas.ย
1. Check packaging usage daily
Order numbers only tell part of the story. A change in what customers buy can affect packaging requirements even when total sales stay close to forecast.ย
For example, customers may start buying products as a bundle instead of individually during a promotion. You could have enough boxes overall but too few in the size that fits the new order combination.ย
Each day, check:ย
- Usage of your busiest packaging formats.ย
- Remaining stock and confirmed delivery dates.ย
- New products, bundles and customer requirements.ย
- Damage, repacking and unexpected material use.ย
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Tell your supplier as soon as you see a change. An early conversation gives more time to assess the production and delivery options. Improved efficiency across our new and existing facilities gives us more room to respond when volumes change.ย
2. Identify what you need to keep orders moving
When a shortage looks likely, establish which packaging is critical and when it will run out.ย ย
Send your supplier the dimensions, material specification, quantities and required delivery date. Include drawings, samples or photographs where available. Explain whether the full quantity is needed immediately or whether the initial delivery could cover the more urgent orders.ย
This helps distinguish between a requirement for more of an existing design and a new specification. Our new, larger Cannock headquarters and increased production capacity give us more flexibility to access urgent requests like these.ย ย
Our packaging solutions for logistics and fulfilment help businesses adapt to changes in their product ranges and order volumes.ย
3. Check alternatives before changing the packing method
Using the nearest available box can create extra work. An unsuitable size may need more filler, take longer to pack or leave products poorly protected.ย
If your usual format is unavailable, check any alternative against:ย
- Product dimensions, weight and vulnerable areas.ย
- Required strength and stacking conditions.ย
- Packing time and material use.ย
- Pallet layout and delivery requirements.ย
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Trial it first before introducing it across the operation. Give staff clear instructions so temporary changes are applied consistently.ย ย
Our guide to 5 signs your packing process needs to be reassessed explains where avoidable handling and repacking can build up.ย
4. Make space before stock arrives
Additional packaging needs somewhere to go. Bringing in more stock without planning its location can leave packing benches crowded and useful formats difficult to reach.ย ย
Agree delivery quantities around the space you have. Keep frequently used packaging at the point of use and reserve stock in clearly labelled locations.ย ย
If your range has become difficult to manage, review whether you can standardise some formats without compromising protection. Read how packaging standardisation simplifies stock storage.ย ย
5. Review the whole packaging journey
A quick packaging decision can affect peak Black Friday and Christmas logistics at several stages.ย
Use our 5 pillars of supply chain efficiency to check the wider impact.ย
Pillarย | What to check during peakย |
Pickย | Can staff find and access products easily? Additional pick bins may help organise temporary picking locations.ย |
Storeย | Can extra products and packaging be held without blocking working areas?ย |
Packย | Is it easy to assemble and use consistently?ย |
Shipย | Does it protect the product and suit pallet handling? Review pallet boxes where suitable.ย |
Returnย | Will returns need replacement packaging, and could a reusable solution work?ย |
The aim is to resolve the immediate problem, maintain service levels and keep the rest of the operation working efficiently.ย ย
Why investment helps when plans change
A supplierโs ability to respond during peak times depends on the facilities, equipment and processes behind production.ย
At Lesters Packaging, our move into a significantly larger headquarters facility in Cannock, alongside ongoing investment in machinery and manufacturing technology, has increased production capacity. Improvements across our new and existing facilities also strengthen operational efficiency, resilience and flexibility.ย
For our customers, this means we are better positioned than ever to support additional, urgent or unexpected packaging requirements during busy periods.ย
The right response will depend on the specification, quantity and timing. That might involve reviewing further production of an existing format or discussing bespoke packaging where requirements have changed. Clear information helps us establish what is achievable.ย
Support when your peak plans change
Peak season rewards good planning, but it also demands flexibility. Our investment in facilities, equipment and capacity strengthens our ability to support both planned requirements and unexpected demand.ย
Managing peak demand doesnโt have to be stressful. With the right packaging solutions, your business can handle high-volume periods efficiently. Contact us today to learn more about our bespoke packaging solutions and how we can help you thrive during peak demand.ย ย ย
If your packaging requirements have changed, tell us what you need, how much you need and when you need it. We can assess the options with you and help keep products moving. When the pressure is on, we’re ready to help.ย ย
Get in touchย ย ย