Why this matters now 📦
If you’re a growing manufacturer, chances are your product’s in demand.
Orders are coming in. New customers are lined up. Forecasts are ambitious. So far, so good.
But there’s one question that can quietly derail even the best growth plans:
👉 Do you actually have the packing capacity to keep up?
We’re not just talking about today. We’re talking about the next promotion, the next big account, the next jump in volume.
Because if your production ramps up… and your packing can’t match it… Your whole operation slows down.
This blog will help you sense-check that before it becomes a problem.
Why packing gets overlooked — and why it matters 👀
Packing is often seen as the final step in the process. A box to tick. A space to fill.
But in reality, it’s one of the most common bottlenecks we see in scaling manufacturers.
That’s because it rarely gets the same level of planning as production.
It starts small:
- A couple of lines in the corner
- Teams jumping on to help when needed
- A “we’ll figure it out” mindset
But as complexity grows, packing quickly becomes a source of stress.
And it shows up in familiar ways:
❌ Overtime creeping up
❌ Deadlines being missed
❌ Floor space swallowed by pallets
❌ Managers spending more time juggling layouts than leading teams
That’s when manufacturers realise they haven’t just grown their product line.
They’ve grown a packing operation by accident.
5 signs your current packing setup is holding you back 📦
You might not have hit breaking point yet. But here are 5 signs it’s not far off:
1️⃣ You’re saying “yes” to every job — and holding your breath
If every new order leads to last-minute planning chaos, the cracks are already there.
2️⃣ Your teams are constantly switching roles
If people are being pulled from improvement projects to jump on the line, productivity (and morale) takes a hit.
3️⃣ You’re relying on one or two “go-to” fixers
When packing runs well only because certain people know how to make it work, you’re vulnerable.
4️⃣ You’ve started talking about needing more space or kit
Extra units and equipment are a huge investment. But are they the only way?
5️⃣ The team’s too busy to step back
If there’s no time to analyse, improve or plan ahead, growth becomes guesswork.
If a few of these ring true, now’s the time to explore your options — before another peak hits.
What outsourcing can unlock (when done right) 🚀
Outsourcing packing isn’t a last resort. It’s a deliberate decision to scale without adding more pressure internally.
At Excel, we work with manufacturers who want to:
✅ Free up space for production, not storage
✅ Avoid big capital outlay on conveyors, labellers and printers
✅ Reduce overtime and short-term fire-fighting
✅ Get predictable capacity from a team who does this day in, day out
✅ Focus on growing the core of their business — not running a packing line
We don’t just “do” packing. We become the packing arm of your business — with the people, kit and systems ready to go.
How to evaluate your real capacity 📊
If you’re not sure whether it’s time to outsource, start here:
Ask yourself:
- What’s our average monthly volume — and what’s forecasted for Q2/Q3?
- How many hours does our team spend managing packing vs. improving processes?
- Are we using valuable space for packing that could be used for production?
- How much did we spend last year on repairs, overtime, or agency labour for packing?
Now imagine those numbers shifted. Where would that time, money and space go instead?
That’s where the real ROI of outsourcing sits.
Final thoughts: this year, make a deliberate choice ✅
Outsourcing isn’t for everyone.
But the worst place to be is stuck in “just about managing” with no clear plan.
If packing is the thing that blew up your plans in 2025, it doesn’t have to in 2026.
Let’s get ahead of the next volume spike and make a plan that actually works.
📩 Get in touch to book a free walkaround at Excel HQ.
We’ll look at your current pain points, map out the numbers, and be honest about whether it’s the right move.
