Product Guide

Case Study: How One Retailer Cut Packing Time by 40% with Crash Lock Boxes

How switching from standard boxes to crash lock packaging transformed one retailer fulfilment operation.

4 min readUpdated April 2025

The challenge

A mid-sized UK e-commerce retailer shipping 2,000+ orders per week was struggling with slow packing times and inconsistent parcel presentation. Their fulfilment team was spending too long assembling standard folding boxes, taping bases, and dealing with boxes that collapsed during packing. Each box took 30-45 seconds to assemble before any product could be placed inside.

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30-45 seconds per box to assemble standard folding cartons with tape
High tape consumption adding ongoing material cost to every order
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Inconsistent presentation with uneven folds and messy tape lines
Training new staff took days because assembly technique varied between workers

Quick answer

By switching to crash lock boxes, the retailer reduced per-box assembly time from 30-45 seconds to under 10 seconds. This 40%+ reduction in total packing time freed up staff capacity, eliminated tape costs for base sealing, improved parcel consistency, and reduced new-staff training time from days to minutes. The slightly higher per-unit box cost was more than offset by labour savings.

The solution

The retailer trialled crash lock boxes in three popular sizes covering 80% of their product range. The crash lock base design eliminated the need for tape on the bottom of each box, and the one-step assembly meant any team member could prepare boxes instantly with no training.

The crash lock mechanism snaps the base flat instantly. No tape, no folding technique required.

Base tape was eliminated entirely. Only lid closure tape was still needed.

No assembly technique to learn. Pick up the box, push the base, done.

Want to understand the efficiency benefits? Read how crash lock boxes reduce labour costs in fulfilment centres.

The results

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40% reduction in total packing time across the fulfilment operation
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50% reduction in tape usage saving both material costs and time
Consistent, professional presentation on every parcel with clean lines and no messy tape
Training time reduced from days to minutes for new fulfilment staff

Key lessons

Takeaways for your business0 / 4 checked

Calculate total cost including labour, not just per-box price - crash lock boxes often save money overall
Trial with your highest-volume sizes first to see the biggest immediate impact
Measure before and after - track assembly time, tape usage, and error rates
Get staff feedback - packers usually prefer crash lock boxes and work faster with them
From ProcuraPack

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Frequently asked questions

Typically 40-60% reduction in assembly time compared to standard folding boxes that need tape on the base.

Per unit, slightly. But the labour savings and tape reduction usually make them cheaper overall.

They are available in a wide range of sizes. Most businesses find 3-4 sizes cover 80%+ of their product range.

Immediately. The one-step assembly requires no training or technique.

Yes, the locked base provides consistent structural integrity compared to hand-taped bases which vary by packer.

Related articles

Reducing Labour Costs in FulfilmentCrash Lock vs Standard Folding CartonsWhy E-commerce Brands Are SwitchingCost Comparison: Crash Lock vs Manual Lock

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Product Guide: Crash Lock Boxes

Expert insights on crash lock packaging, from materials and design to branding and sustainability.

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