How Four Ontario Manufacturers Reduced Per Pack Cost with Protect It Right

Case Study: Manufacturing


When it comes to protective packaging, there’s a fine line between secured and susceptible.

Shipping, handling, delivery — there are many points on a product’s journey where damage can occur. But with the proper protection, manufacturers can trust that their products will arrive safe and secure.

In the case of the following four manufacturers, Crawford was able to harness the power of its Protect It Right program and Sealed Air’s innovative SpeedyPacker® technology. Each manufacturer had a unique problem, but thanks to Crawford, were able to ensure product security, improve packaging efficiency, and dramatically lower cost-per-pack.


Protect It Right

Protect It Right audits and reviews existing protective packaging practices, materials, and equipment. The program identifies areas of inefficiency and offers improvements to increase productivity and reduce per pack costs. Through this program, clients have discovered ways to reduce their costs by up to 30%.



As one of many products offered under Crawford’s Protect It Right program, SpeedyPacker®’s foam-filled bag dispenser system is among the most customizable. Made by Sealed Air and paired with their Instapak® foam, SpeedyPacker® is a cost-effective option that provides consistent and effective protection. From the most delicate to most heavy-duty, adding this unparalleled layer of protection will defend your products from the damage of shipping.


Case #1: Elevator Button Panels

A Cambridge, Ontario manufacturer was receiving complaints from clients about damaged products as a result of delivery. This was due to ineffective protective packaging that couldn’t keep the items secure in their corrugated boxes.

Crawford’s Packaging Specialist conducted a Protect It Right audit which revealed an opportunity to use Sealed Air’s SpeedyPacker® to keep the products safe. After reaching out to the supplier, Sealed Air borrowed a sample product the manufacturer and brought it to their Charlotte, N.C. packaging lab. After running tests and designing a working model, a full solution was sent to the manufacturer, including a prototype Instapak® foam insert, detailed report, video instructions, and cost breakdown.

After adopting the proposed solution, the manufacturer saw a dramatic decrease in reports of shipping damage. Also, thanks to the quick and efficient nature of SpeedyPacker® and Instapak® foam, operations have sped up and throughput is more consistent.

Case #2: Water Delivery and Treatment

With a new branch opening, another Cambridge manufacturer wanted to shift from their U.S. supplier and gain the advantage of dedicated local support. Also, unbeknownst to them, the manufacturer was being sold an incorrect foam density that was driving up costs.

After reaching out, a Crawford Packaging Specialist worked with a Sealed Air representative to conduct a thorough audit of the manufacturer’s needs. They determined that by switching to Instapak® and choosing a lower density foam, the manufacturer could save on ongoing material costs.

The manufacturer was thrilled with the professionalism and expertise brought by both Crawford and Sealed Air. From the audit, installation, training, and ongoing tech support, the manufacturer was impressed with how responsive and dedicated the representatives were.

Case #3: Diesel Particulate Filters

Pre-cut foam was wasting too much floor space — and money — for an Innisfil, Ontario manufacturer. Also, since the manufacturer needed versatility to ship different products, pre-cut film was slow to order.

A Crawford Packaging Specialist was called in to assess the situation and conduct a Protect It Right audit. It became clear that the perfect solution would be the SpeedyPacker® system, as it would create custom, form-fitting protective packaging for any product the manufacturer produced. Similarly, since Instapak® foam elements are kept in barrels, as opposed to arriving pre-cut, the manufacturer could drastically reduce the amount of floor space needed to store packaging materials.

Once implemented, the manufacturer saw immediate results. Floor space was drastically freed up in their warehouse, allowing for more storage of product instead of packaging foam. Also, Instapak® allows the manufacturer to use what they need — no more, no less. That eliminates unnecessary costs of ordering pre-cut foam.

Case #4: Manufacturing Instrument Components

A Sarnia, Ontario manufacturer was using a hand-held foam dispenser in the hopes of keeping their products safe. This was a slow process that created inconsistent and unreliable foam inserts that couldn’t be trusted to secure products during shipping.

Crawford’s Packaging Specialist was called in to conduct a Protect It Right audit in the hopes of finding a more efficient and effective alternative. Once complete, the audit showed that the manufacturer needed to switch to a foam bagging system instead, as it would allow them to improve throughput. It was recommended that the manufacturer switch to Sealed Air’s SpeedyPacker® system, which uses Instapak® for a fast foam fill.

After adopting the system, the manufacturer greatly improved packaging operations. They saw improved efficiency and a much higher packs-per-hour speed, less downtime, and a far lower consumption — SpeedyPacker® uses the exact amount of foam needed. Also, thanks to Crawford and Sealed Air, the manufacturer has access to local, knowledgeable support for fast problem resolution.