- The Polyformes Blog
- Is your packaging operation ready for peak season?
Every year, from November through January, UK businesses experience what's known as peak season; a period of high demand driven by events such as Black Friday, Cyber Monday, Christmas and the January sales.
Every year, from November through January, UK businesses experience what's known as peak season; a period of high demand driven by events such as Black Friday, Cyber Monday, Christmas and the January sales.
While increased orders are great news for sales, they can also place huge pressure on warehouse operations, especially when it comes to picking, packing and dispatch. Fulfilment teams face:
To stay efficient, sustainable and customer-focused, your packaging operation must be ready well before the first order surge hits.
The best time to prepare for peak season? Right now.
By reviewing previous performance and forecasting demand early, you can:
At Polyformes, we often see that early planning of packaging materials helps businesses avoid last-minute shortages and improve warehouse productivity.
Your warehouse layout directly affects picking accuracy and fulfilment speed. Consider reorganising fast-moving lines closer to dispatch areas and using custom foam trays or tool control inserts to streamline assembly or packing.
Smart layout planning reduces wasted movement, improves accuracy, and helps temporary staff stay efficient during peak.
Downtime is the enemy of efficiency. Before the season starts, service or repair:
A short maintenance check now prevents long disruptions later.
Packaging is often where efficiency gains are easiest to achieve. Review:
Switching to custom-cut foam inserts or bespoke trays can dramatically reduce packing time and material waste, while improving presentation and protection.
Speed is key, but protection matters just as much. Use fit-for-purpose foam solutions designed to:
Foam inserts also help staff pack consistently, which is vital when working with seasonal labour.
Today's customers expect businesses to think beyond performance, and eco-friendly packaging matters. Polyformes offers a range of recyclable and re-usable foams, such as ARPLANK and cross-linked polyethylene (XPE), that help businesses:
Switching to recyclable foam packaging can also help your brand stand out during the busiest months of the year.
Seasonal staff often have limited training time. Create clear, visual guidelines for packaging processes, including which cases, foams and materials to use for each product type. Structured onboarding ensures consistency and accuracy across all shifts.
Returns can double during peak periods, especially if products are damaged in transit. Using engineered foam packaging reduces movement, absorbs impact and prevents costly breakages, keeping both your customers and your operations team happy.
Automation doesn't have to mean robotics. Small changes, like automated taping or void-fill systems, can free up valuable staff time and reduce repetitive strain. Combining automation with pre-cut foam inserts can speed up fulfilment without compromising quality or protection.
Once the peak period ends, gather insights. What worked? What slowed you down? Regularly reviewing your packaging efficiency, warehouse layout and material choices will set you up for continued success, and make next year's peak season even smoother.
Preparing your warehouse for peak season isn't just about speed, it's about efficiency, protection and sustainability.
At Polyformes, we help businesses across the UK and Europe optimise their packaging operations with custom foam inserts, trays and engineered packaging solutions. Whether you need bespoke case inserts, protective dunnage or sustainable foam materials, we'll help you protect your products—and your reputation—when demand is at its highest.
Contact us today to discuss your packaging challenges ahead of peak season. Let's make this year your most efficient yet!