Packaging efficiency solutions Australia is becoming essential as manufacturers respond to rising fulfilment volumes, stricter sustainability targets, and increasing regulatory pressure.
For in-the-box fulfilment, many operations face the same challenge. They need to protect products while freeing up warehouse space and reducing waste. At the same time, they must keep packing lines moving efficiently.
To address this, Sealed Air’s on-demand systems replace bulky, static cushioning materials such as paper or loose-fill. Instead, they generate protective packaging only when and where it is needed. As a result, businesses gain precision protection without unnecessary material use.
For fragile, heavy, or high-value products, Instapak® Foam-in-Place technology delivers tailored protection. The system creates a custom-moulded foam cushion that blocks and braces the product inside the carton.
As a result, operations benefit in several ways:
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Maximum space savings: Instapak® uses concentrated liquid resin that expands up to 280 times its original volume. Consequently, a small resin drum can replace multiple truckloads of traditional cushioning, freeing valuable warehouse floor space.
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Precision protection: The foam locks the product firmly in place. This prevents movement during transit and significantly reduces damage, which is critical for long-distance freight across Australia.
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Versatility: Instapak® offers 15 specialised foam formulations. These range from light cushioning, such as UltraLite™ Foam, to heavy-duty blocking and bracing solutions like Instapak® 75W Foam.
For lightweight to medium-weight goods, Fill-Air® systems focus on speed and simplicity. In particular, the Fill-Air Rocket™ sets a new benchmark for packing efficiency.
Key benefits include:
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Unrivalled speed: The compact system produces air cushions at up to 30 linear metres per minute. Therefore, the packing station never becomes a bottleneck.
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Dimensional weight control: By using only the required amount of ultra-light cushioning, operators can avoid oversized cartons. This directly helps reduce costly dimensional weight (DIM) charges from major carriers.
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Waste minimisation: After use, Fill-Air® cushions deflate to less than 1% of their inflated size. This improves the end-user experience and reduces disposal volume.
Futureproofing Your Protective Packaging Strategy
As Australia’s circular economy accelerates, packaging decisions must anticipate future regulations and operational demands. Increasingly, businesses are turning to smarter, data-driven, and automated solutions.
Key trends shaping the future include:
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Mono-material design: There is a strong shift toward packaging made from a single material, such as polyethylene films. This simplifies recycling and improves recovery rates.
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Reusable and refillable systems: Beyond retail, returnable transit packaging (RTP) and reusable crates are gaining traction in industrial supply chains. These systems reduce single-use plastics and streamline picking operations.
Integrating Today’s Technology for Tomorrow’s Goals
The technologies we support at MPI Australia align closely with these trends.
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Cryovac® CT films and mono-materials: Cryovacovac CT Microlayer films are fully recyclable as LDPE #4. Importantly, they help businesses move away from non-compliant, multi-material wraps.
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On-demand systems and automation: The speed of the Fill-Air Rocket™ and the precision of Instapak® Foam-in-Place make them ideal for robotic pick-and-pack stations. MPI Australia specialises in configuring these systems to integrate seamlessly with Warehouse Management Systems (WMS).
By combining material innovation and automation, it can help manufacturers increase throughput while reducing waste and compliance risk.
Adopting advanced packaging solutions is more than an operational upgrade. It is a strategic investment in efficiency, cost control, and long-term compliance.
At MPI Australia, we go beyond supplying equipment. We provide the expertise to integrate high-performance systems into existing production lines, ensuring a smooth transition and a fast return on investment.
Contact MPI Australia today:
Call (02) 9648 3011 or visit www.mpiaust.com.au
