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"WE’VE SEEN A
REDUCTION OF
73.6% IN PLASTIC"
PETER NEWBY, DISTRIBUTION SITE MANAGER AT CARPETRIGHT
Load Stability
OBJECTIVES
When Carpetright identified the need to reduce plastic usage and overall load-stability costs, they sought a partner capable of delivering in-depth analysis and proven solutions—not just a cheaper film.
By collaborating with Castle Industrial Supplies, Carpetright aimed to achieve the following:
REDUCE PLASTIC USAGE
LOWER OVERALL WRAPPING COSTS
UPGRADE MACHINERY
TEAM
Ben Thompson
TECHNICAL MANAGER
JAMIE HOLROYD
ACCOUNT MANAGER
ALISDAIR DODDS
LOAD STABILITY SPECIALIST
PROCESS
Facing the plastic challenge
Carpetright had been using a 30-micron stretch wrap from another supplier. While the film was serviceable, the company recognized two critical issues: it was more plastic-intensive and more expensive than necessary. Carpetright wanted comprehensive testing and data-driven recommendations—not simply a lower-cost product.
Castle Industrial responded with an on-site analysis of Carpetright’s existing processes and machines. These tests demonstrated the feasibility of using a significantly thinner 15-micron film without compromising load stability.
Written by
Kamila Skrzypek
Partnering with Castle Industrial
After the initial stability tests, Castle presented Carpetright with a full report detailing potential cost savings, plastic reduction, and load-stability improvements. Carpetright’s team quickly recognized Castle’s approach as best in class, backed by real data rather than just cost-based promises.
With Castle’s guidance, Carpetright adopted a 15-micron film in place of the original 30-micron wrap. In addition, Castle highlighted inefficiencies in Carpetright’s existing pallet-wrapping machines, leading to the purchase of two new machines.
Written by
Jamie Holroyd
Achieving plastic and cost savings
Switching from a 30-micron wrap to a 15-micron wrap resulted in a remarkable 73.6% reduction in plastic usage, equating to approximately 21 tonnes of CO₂ savings per year. From a financial standpoint, Carpetright saw a 52% decrease in wrapping costs—around £19,000 in annual savings.
The new, thinner film maintained excellent load stability, ensuring that pallets remained secure during transport while contributing to Carpetright’s sustainability goals.
Written by
Aaron Entwistle
Setting a global standard
By implementing Castle’s recommendations and upgrading their machinery, Carpetright not only improved operational efficiency but also made a significant stride toward more sustainable practices. The successful outcome—substantial cost reduction, improved load stability, and sharply lower plastic consumption—positions Carpetright as a leader in sustainable distribution.
This case study underscores Castle Industrial’s ability to combine product innovation, technical support, and in-depth testing for long-term results. Carpetright’s experience exemplifies how an investment in expert analysis and modern machinery can drive both environmental benefits and bottom-line gains.
Written by
Ben Thompson
We switched to Castle’s 15 micron plastic which saved 52% on costs.
PETER NEWBY
Distribution Site Manager
Data-Driven Testing & Analysis
The team provided onsite load stability and wrap efficiency tests, proving their solution’s value.
Significant Cost & Plastic Reduction
Carpetright saw immediate savings of 52%, alongside a sharp drop in plastic usage.
Ongoing Support
& Innovation
Recommended vital machinery upgrades and continue to provide technical advice.