As a business we have a mission to provide completely plastic free packaging solutions that are paper based, From corrugated packaging to paper tapes. Paper and corrugated are some of the most recyclable materials you can use for packaging. Also, materials that have been marked as FSC-certified will be sourced from sustainably managed forests, keeping natural resources protected, and contribute towards the safety of the environment.
Therefore, as providers of corrugated and paper products, an FSC certification seemed an appropriate demonstration of our commitment to responsible source for our customers and business. As we are FSC Chain of Custody Certified, you can buy corrugated boxes and packaging from us with sustainable reassurance.
“Drive towards sustainable packaging”
It is essential to businesses now, especially those in e-commerce who are selling online to make their packaging as green as their products, to reduce, reuse and recycle. By reflecting these values not only do you help the environment, but also increase brand loyalty amongst your eco-conscious consumers.
What is zero waste packaging
So, what exactly is zero waste packaging? Zero waste packaging refers to a system of packaging where all materials are utilized, recycled, or reused, so that no-waste products are created.
How does Challenge Packaging work towards zero waste packaging? Well, we recycle all of our waste corrugated and paper into new product, as well as maintaining the cleanest levels of hygiene within our manufacturing process, recycling and reusing the water used in our printing processes. These approaches are just some of the ways we contribute towards reducing the amount of waste generated and the need to recycle in the first instance.
Our Top 4 Plastic Free Packaging Products
Sustainable packaging design is designing product packaging with the main purpose of doing as little harm to the environment as possible, and believe it or not, most money can be saved by using less packaging.
Our product development team have been monumental in sourcing us plastic free product solutions. Below we have picked out our top 4 from the last 12 months:
1. Protega Eco-Friendly Protective Paper Cushioning – “NO more void fill waste!”
Remove the need for plastic product protection, such as traditional bubble wrap with this paper cushion that prevents damage to goods whilst in transit. The Protega machine produces a paper cushion that compresses less than any other alternative of the same size, meaning you can minimize the use of resources to protect your products.
We have two Protega machines that you can choose from in our product range, the Protega 200 cushion and the Protega 125 cushion. The Protega 200 is best for heavy-duty applications where a wide cushion is required. The Protega 125 is best used for general purpose applications and use in small to medium boxes.
Make sure that you use the right techniques with Protega paper cushioning which will save you time, reduce wastage, and ensure you protect your good correctly. Protega allows you to use less packaging whilst still protecting your products and creating an environmentally friendly open box experience for your customer.
Quite simply put, by using less material no matter how sustainable it is, you are being more environmentally friendly just by using less.
2. Hexcel – Paper Bubble Wrap – “No more non-recycled bubble!”
Your customers will thank you with this sustainable, reusable, compostable and recyclable product; a fully green wrapping product, Hexcel is the next generation of protective wrapping. A 100% recyclable and biodegradable material, this paper wrap is designed to replace plastic bubble wrap.
Giving you source reduction by reducing wrap and void fill packaging, saving you time, money, space, and logistics. Hexcel also eliminates the need for taping, so if you were not using our paper tape beforehand, you can create a fully recyclable product by using one of our cardboard boxes and Hexcel protective packaging.
3. Paper Tape – “Say NO to plastic tape, now that we have a new paper option!”
A self-adhesive tape made of brown paper that is not chlorinated nor bleached, the adhesive is made of special rubber, the tape of paper, making it 100% biodegradable as well as 100% recyclable.
With its maximum conformability, our paper tape has excellent adhesion on irregular surfaces and is resistant to accidental knocks. It does need a tape dispenser as it can be torn by hand, however, we do stock tape dispensers if that is what your business needs to ensure optimum performance.
4. Environmentally Friendly Insulated Boxes – “NO more polystyrene!”
Protect your food items during transit keeping them healthy and fresh from dispatch to delivery.
A curb side recyclable packaging solution developed for shipping pre-packaged, temperature sensitive goods. The product’s thermal insulation is constructed from heavy-duty kraft paper containing uniform inner padding, providing superior insulating properties.
Their superior insulation properties maintain temperatures during the journey.
A fully recyclable product, made from 100% recycled newspapers, so you can place the box and packaging directly in the recycling bin. With disposable packaging, once the product has been opened, you can create an easier more sustainable customer experience from start to finish.
With the public becoming more aware about sustainability issues and waste caused by bad packaging, wasteful brands are being named and shamed. Which is why our objective is one of proactivity, we are making every effort to bring our paper-based products to supersede plastics. Hence making it easier for you, your business and brand to reduce its carbon footprint, by using our range of plastic free packaging.
All our boxes are made from corrugated board, so create a full recyclable experience with paper based protective packaging, corrugated box, and paper tape.
“Creating sustainable packaging innovations”
We have set ourselves a goal to be plastic free, we are pleased to introduce the latest addition to our plastic free range… our new Self-Adhesive Paper Tape!
As we transition to eradicate plastics across our business, we are offering more environmentally friendly alternatives that add value to your business. We will be continuing with the sale and distribution of our plastic tape range for the time being, but, the arrival of our new Self Adhesive
Paper Tape means that you can offer complete hassle packaging, with one our cardboard boxes sealed with our Self Adhesive Paper Tape. A 100% recyclable product, plus the excellent quality of our products means you get to send a product that ensures a great customer experience from the
point of delivery.
Our Self-Adhesive Paper Tape is a self-adhesive tape made of brown paper that is not chlorinated nor bleached. The adhesive is made of natural rubber, and the tape is made of paper, making it 100% biodegradable as well as 100% recyclable. Due to the quality of the paper and the high tack
adhesive, you are able use this Self-Adhesive Paper Tape across a wide range of products and boxes of all shapes and sizes.
It is sustainably sourced too, as the paper is recycled so no trees have been cut to make the tape. Not only is it eco-friendly, but our paper tape is also FSC certified. FSC is the world’s most trusted sustainable forest management solution. They allow consumers and businesses to make informed
choices about the forest products they buy. Thus, enabling positive change by engaging the power of market dynamics.
Self-Adhesive Paper Tape can be torn by hand; however, we do stock tape dispensers if you want to improve efficiencies within your business and optimum performance. Our Self-Adhesive Paper Tape will even perform at low temperatures.
Our Self-Adhesive Paper Tape is available for print with water-based inks, which means you can benefit from bespoke messaging or print your company logo on to the tape, to optimize brand awareness and consistency on the outside of your packaging as well as inside whilst still remaining
Fast and easy to pack with, Hexcel Wrap reduces pack time, minimizes breakages and is eco-friendly! Made from paper, the most sustainable, reusable, compostable and recyclable material on the planet.
What is Hexcel Wrap?
Hexcel Wrap is the next generation of protective wrapping and is designed to be a sustainable alternative to bubble wrap with a 100% recyclable and biodegradable material content.
Hexcel Wrap eliminates damage with exceptional protection. The hexagonal cells create an interlocking web that surround and protect all your items, because of this interlocking web no tape is required. It allows you to reduce your wrap and void fill packaging to just Hexcel, saving space, logistics, time, and money.
One roll width is all you need in Hexcel Wrap. This is because our roll is the optimum width when wrapping with two hands. If the Hexcel Wrap roll were wider, the outside edges would not stretch effectively creating wasted material.
To Summarise The Main Benefits Of Hexcel Wrap:
• The environmental alternative to bubble wrap
• Simple compact dispenser, for easy loading and fast use
• Unique cut system creating cells offering high protection
• Unique cells binding to each other – no tape needed
• Easy wrapping
• 100% degradable and recyclable paper
• Less material needed than bubble wrap and bubble fill
• Easy storage
At Challenge Packaging we are delighted to announce that we have passed this year’s BRC audit, retaining our AA grade. This is the maximum grade we can achieve without an unannounced audit.
The BRC Standard for Packaging Materials has been updated this year to Issue 6 which has seen refinement on several clauses which inevitably makes the standard stricter as the BRC continues to expect a higher standard maintained by companies.
This is an amazing achievement by all the team at Challenge, who continue to apply and commit themselves daily. We are very proud of all who work at Challenge and how they continue to contribute towards the welfare of the business. We are focussed on the quality and safety from the ground up within our organisation.
It is important to note, that during these challenging and exceptionally health-conscious times, the BRC standards are higher and stricter than ever. To achieve top marks, you have to be able to show only the highest commitment and safety policies. To demonstrate, how much we have the safety and wellbeing of internal teams, visitors, and the public at heart. Our new BRC AA grade exemplifies this and our continued commitment to this cause.
The BRC standard is more than just a system to monitor cleanliness and hygiene in our environment, and these days covers our business in its entirety from enquiry, right through to delivery, as well as all of the supporting functions.
The BRC standard was created and published in 2001 and became the Global Standard for Packaging Materials, designed to protect the consumer by enabling a basis for the certification of companies supplying packaging to food producers. This standard provides a powerful framework for all types of packaging manufacturer to assist in the production of safe packaging materials and to manage the quality of their products whilst meeting the customer’s requirements yet maintaining legal compliance at the same time.
To achieve the certification and compliance with Issue 6, you need to have performed within these six sections:
1. Senior Management Commitment – For packaging quality management to remain effective, management needs to be fully aware of the requirements and must commit to the implementation
2. Hazard and Risk Management System – An effective hazard and risk analysis
3. Product Safety and Quality Management – Requirements for the technical management of product quality and hygiene practises
4. Site Standards – Expectation for the production’s environment including the assessment of building layout, maintenance, cleaning, and waste
5. Product and Process Control – Product inspection and testing
6. Personnel – Standards for staff training, protective clothing, and hygiene
By having this standard, you can be assured that your business and consumers are buying into product safety and quality management. This standard is recognized globally, so you can trust in a quality management programme and supply chain management.
“The perfect plastic free alternative to bubble lined mailers or bags”
Our eco-friendly capacity mailers are manufactured from 100% recyclable micro-flute, giving a high level of protection and premium user experience. These are the most environmentally friendly envelopes within the packaging market, check out range extensive range, ready for immediate dispatch.
“100% Recyclable and PLASTIC FREE!”
Made from 100% recycled material which is also FSC, they can be recycled or even composted at home after use. Our mailers are 100% plastic free, so buying from us, you will be demonstrating that you comply with the highest environmental and social standards in the market.
We are proud to say our capacity mailers are PLASTIC FREE Ocean Friendly and can even be composted at home once used, all our mailers are printed with our water-based ink too! By sending your products in plastic-free packaging you are contributing to the removal of single use plastics that are have a significant effect on our ecosystems.
You can reduce your postage costs with these mailers, our new range of sizes with expanding capacity allow you to package up items without the use of void-fill packaging. Each of the sizes within our new Capacity Mailer range are compliant with the Royal Mail PIP (Pricing In Proportion) guidelines, so you can have a clear idea of postage costs.
“Royal Mail PIP Compliant!”
The innovative design of our capacity mailers allows easy use of envelope form, or you can utilize the capacity element of the design, giving you the prefect mailer. Our latest self-seal for secure closure feature with tear strip makes these mailers easy to assemble and frustration free.
“Easy to use!”
Send a wide variety of products such as books, documents, pictures, DVDs, brochures, and other products, and protect your items from being folded, bent, or creased during the transit.
Benefit from long term protection at affordable rates with our modest range of book mailer wraps. We offer eight different sizes of book mailer wraps, with bulk order options starting from as little as 14p per book mailer wrap.
Book Mailer Wraps
Book mailer wraps are the ideal packaging product for:
• Books of all different sizes and weights
• Steel books
If you are selling books, DVDs, and other multimedia products online, then you will be searching for the best packaging for posting and distributing your product sales, and we will not be beaten when it comes to purchasing price and product quality.
Challenge Packaging are well-regarded as providing the best value packaging solutions to UK markets. Ultimately, we want our customers to be as happy as your customers.
For those of you in search of a bargain, you will be pleased to know our book mailer wraps are cheaper than Amazon! Our smallest book mailer wrap is our ASCMP00C1 225mm x 155mm x 55mm, and costs just £11.50 for a pack of 50.
View Our Book Mailers
Amazon offers a small book mailer wrap that is 216mm x 154mm x 55mm for £50.99 for a pack of 100. With our affordable pricing, you could get 250 mailers with us for the cost of £50, giving you a premium, sustainable product at a much better price!
Save On Costs When You Buy From Us
“Great quality cardboard, at a great price”
Our book mailer wraps are used by hundreds of booksellers, publishers, and internet sellers. Because they wrap around their contents, book mailer wraps have varying internal dimensions making them great for circumstances where the combination of shipped goods may change, or if you're looking for a cardboard box that consolidates your packaging use, all while using a premium material at a great purchase price.
““Buy more, Save more”
Buying with us does not just mean saving on money, but saving on time, and even contributing towards saving the planet! Our book mailer wraps have been designed and then manufactured with simplicity in mind. They are easy to put together, delivered flat with an integral self-seal strip that allows for a secure closure, yet all the protection you need whilst your product is in transit.
Our book mailer wraps are manufactured from corrugated cardboard, all of which are recycled material, and are 100% recyclable and biodegradable. Therefore, you can help to save time for the customer with a fully discardable product once it has been opened.
Our book mailer wraps are also FSC accredited, which shows our dedication to a greener, more sustainable environment. Buying from us means you contribute to that same sustainable and environmentally friendly process.
A little bit more about the ‘Book Mailer Range’…
In addition to our book mailer wraps, we also have ‘Twister Mailer Packs’ within our Book Mailer range. These are slightly cheaper than our book mailer wraps, with some cost per unit prices starting at just 8p each! These are manufactured from a tough mottled white corrugated board and are delivered flat.
Twister Mailer Packs
We offer a slightly more variable depth capacity with these mailers and they are a little more flexible with their simple twist and fold functionality. These do not feature a self-seal strip, so you can choose to finish off the closure of this product with tape, glue, or strapping.
Our Book Mailer range boasts all the benefits of a box, they are just easier to assemble, and cheaper to post.
Both our Twister Mailer Packs and Book Mailer Wraps are the perfect solution for eCommerce businesses that operates within the publishing, printing, and media sectors.
By using a cardboard postal mailer from our range, you can create an efficient packaging environment.
"Buy It, Try It, Love It"
View The Range
As manufacturers ourselves, with large operating facilities in East Sussex, we have had to make changes to the way we work and how we deliver products to our customers. Thanks to innovative packaging technology, we have been able to use some of the packaging products we stock, to utilize space, packaging time, and manpower.
Some of our customers have feedback to us about the difficulties they have faced recently when it comes to fulfillment objectives and working with reduced numbers in their teams. Therefore we have put a few ideas together to try and minimise the pressure you may be facing at current.
Decreasing Touch Points
Reduce touchpoints and decrease the areas that you need to sanitize when you purchase our ‘Slimline Protega Machine.’
Reduce touchpoints and decrease the areas that you need to sanitize when you purchase our ‘Slimline Protega Machine.’
The footprint of the slimline Protega machine is not much larger than an office printer (Product reference ‘Protega 125 = 635x360mm’), and fits easily into even the smallest of despatch areas.
The Protega paper cushioning machine produces a paper cushion that compresses a paper cushion less than any other alternatives of the same size. It is proven to prevent damage to goods in transit and gives the end-user a positive open box experience, that is also environmentally friendly.
The Protega paper cushioning machine demonstrates a bench mounted machine that has a carousel fitted underneath to allow rotation of the machine, allowing for easy loading of the replacement paper roll. Limit team members within the facility as well as touch-points when you install one of our Protega machines.
Working with reduced teams/staff?
Reduce the number of people in your packaging operation - for example, you can add an optional attachment, the protega paper cushioning coiler. This is programmed to produce paper coils at preset lengths. Why not invest in a mobile hopper, that catches the paper cushioning lengths, where you can transport them back to the packing bench = a one-person job.
By implementing automated packaging products, you are reducing the amount of manual handling, as well as speeding-up your packaging operations.
With our Protega range, you can benefit from improved control costs, with our automated machinery allowing you to navigate large stock volumes in less floor space. As well as using a fully recyclable void fill product, as Protega only uses paper-based packaging materials.
Need to speed up your Void Fill packaging operations?
Hexcel is the next generation of protective wrapping designed to replace bubble wrap with a 100% recyclable and biodegradable material. This sustainable Paper Bubble Wrap alternative will keep your products in place with its interlocking design without any need for adhesive tape.
What this amazing product gives you is a speedy packaging process, without taping and easy tearing of exactly the right amount, you can expect 25-50% faster packing speeds. Plus, this is another amazing void fill resource that can save you space, up to 80% in fact. This material is delivered flat, as you wrap, the product expands into its engineered hexagonal cells.
Furthermore, you can wrap your items safe in the knowledge that you have eliminated damage with exceptional protection. The hexagonal cells create an interlocking web that traps all your items, as the hexagonal cells keep Hexcel Wrap from unravelling.
Spending too much time ‘Taping Up’?
Our paper tape is a self-adhesive tape made of brown paper that is not chlorinated nor bleached. Our new paper tape is 100% recyclable and creates a strong, durable, and highly adhesive bond.
When you purchase from us. you benefit from packaging that is easy to assemble, pack, and seal, thus increasing the number of packs/boxes that you can process just in a single hour. Our paper tape boasts excellent adhesion, resistant to accidental knocks, and can be torn by hand.
The adhesive is made of special rubber, and the tape is made of paper, making it 100% biodegradable as well as 100% recyclable. Allowing you to offer your customers a fully recyclable product (when purchased with a box from our wide range of boxes) that they can discard with the tape after use.
We offer a wide suite of products designed to help add value to your business, packaging operations and get you to full operating capacity during this unusual time.
Please contact us for any further information or any questions. We would love to hear from you.
The Current long term effects of not reducing our plastic consumption
In the UK there is an estimated 5 million tonnes of plastic used every year, of which nearly half of it is packaging products. Globally there is an estimated 8 million tonnes of plastic used a day, and it is said that by 2050 there will be more plastic than aquatic life in our Oceans.
We have committed to transition our packaging products into plastic-free, where we can. By switching to plastic-free boxes and packaging we could reduce one of the biggest contributors to plastic in oceans.
This is why we have taken steps to transition plastic packaging into paper, plastic-free and recyclable, biodegradable solutions. Such is the seriousness of our commitment to working on selling products that only fuel a sustainable and environmentally-friendly approach, we have created a whole range of plastic-free packaging products which can be found on the homepage of our website, Packaging Online.
One of our 100% paper products that was launched this year with much success is our Hexcel protective wrap. This paper-wrap replaces the need to use bubble wrap. Hexcel wrap reduces the amount of coverage the item needs and doesn't need tape to keep your packaging together, helping to reduce the amount of plastic you use. Hexcel is just one excellent example of where we transitioned a very classic, plastic-made packaging product into a plastic-free alternative.
What does ‘Ocean Friendly’ mean?
If you buy plastic-free products i.e. plastic-free packaging items, you are naturally contributing towards an Ocean friendly policy just by not buying plastic products.
If you are a business that has been given sustainable targets to achieve, you can find out how to further help reduce your footprint, take a look at this website:
We were FSC certified in 2019, something we are immensely proud of. This means that you can be assured that most of our boxes and packaging contain or are made with forest-based materials and are 100% plastic-free. The forests our materials come from are FSC-certified forests where there have been sustainably sourced forest products.
What does this mean for my business?
Buying from us means you can have faith that you are helping the environment every day, hence, making your business more sustainable than it was before. For you, it means you can tell customers that you have an FSC certified product that will show you care and will give you an ethical advantage over competitors. Buying plastic-free, recyclable packaging from us helps reduce ours and your carbon footprint, as well as buying into a circular economy.
For example, buying a box and paper tape from us, even if branded (we use water-based inks) means that you or your customer can discard the whole box with the tape as it is all recyclable. The same applies to if they purchase void fill from us such as protega and Hexcel, it is all paper therefore fully recyclable. It also means you supply them with reusable packaging, as bulky paper packaging is often kept back by customers to use when they want to send something themselves or wrap up a bulky item. Again, fuelling this idea of a circular economy.
If you would like branded boxes for your business or a bespoke package design, we use water-based ink, meaning this will not affect your box's recyclability. This is another demonstration of us helping ourselves and you, to contribute towards a more viable and efficient discardable process for your customers once the packaging has served its purpose.
For any of you who are operating your business out of home, or due to the current climate, have had to transfer your business to your home, did you know we offer more competitive prices than the likes of online giants such as Amazon and eBay. So, if the packaging space is at a minimum, then you can benefit from ordering lower quantities from us, but at great prices.
To give you an idea of just how competitive we are, when we recently researched the Amazon price of book mailers, their small book mailer wraps (216mm x 154mm x 55mm) were £50.99 for a pack of 100. For £50, you could get 250 mailers of a similar size (our ASCMP00C1 225mm x 155mm x 55mm) with us.
So, going back to our statement of offering lower quantities, you don’t need to buy in bulk from us, for that same product you can buy a pack of 50 for just £11.50. And this isn’t even the best bit. Our book mailers are 100% recyclable so you can benefit from lower prices, lower quantities at 100% quality, and environmentally-friendly materials.
What are Water-based Inks and how are these environmentally friendly?
Water-based inks are a non-toxic variant of inks that have no lead or heavy metals in them and they don't use chemicals or volatile solvents that are bad for the environment. It means when we use this water-based ink to print on your boxes, the boxes will stay 100% recyclable,as there is nothing harmful in the inks. Enjoy the benefits of having a branded box without the worry of what it would do to the environment once it has been discarded.
What is the difference between recyclable and 100% recyclable?
A common misconception is that recyclable and recycled are the same thing. This is not the case. A recyclable product is an item that can go into a recycling bin versus a landfill one. A recycled product is an item that already has elements of previously recycled materials.
For a product to be 100% recyclable, it has to be able to go into a recycling process without the need for other processes to take place. If an item is recyclable, it can still be recycled but will need to go through other filtering methods or allow for the breaking-down of material elements before the bulk of the content can be recycled.
Our standard range of corrugated boxes is 100% recyclable which means you don't have to worry about separating the tape from the box or the void fill when you purchase from our plastic-free range of sustainable paper alternatives.
Does this make the product more expensive?
Our products are competitively priced, and we beat larger competitors, such as Amazon, in price while still selling more environmentally friendly boxes and packaging. Not only are we competitively priced but we offer lower amounts of boxes and packing in order than other larger companies do while keeping a lower price that they don't. However the more you buy from us the cheaper they will be!
Do you offer more plastic-free products that are also environmentally friendly?
Besides our Capacity Mailers, we offer a wide array of boxes and packaging that are 100% plastic-free certified by the FSC and are 100% biodegradable such as Void Fill, Bottle Boxes, and even Adhesive Paper tape.
With online sales on the up due to the current Covid-19 crisis, if you are not already selling your stock online, then start thinking about it. Do you have a cafe or locally owned restaurant? Need boxes? No problem. We offer plastic-free packaging for food and drink that will keep all produce safe during travel. We have bottle boxes that come in 6 or 12 sections that will keep your bottle safe during travel. We also offer insulated boxes for food to keep it fresh and safe during travel. These thermal, insulated boxes, boast heavy-duty kraft paper that contain uniform inner padding, which provides amazing insulation that will maintain the correct food temperature during travel.