Pland Stainless
Sustainable, Bespoke Packaging for Multi-Sized Stainless Steel Sinks
Pland Stainless is a leading UK manufacturer of stainless steel washroom and sanitary-ware products. With over a century of heritage and expertise, their products are trusted in industries ranging from healthcare and education to commercial catering and housing.
Since 2016, Greyhound Box has worked in close collaboration with the team at Pland to deliver tailored packaging solutions across multiple product lines. Our latest project involved a complete redesign of the packaging for a series of stainless steel sink units—eight different sizes in total.
This was far more than a simple materials switch—it was an opportunity to rethink how these products are stored, packed, and transported, with sustainability and efficiency front and centre.
The Packaging Challenge
The previous packaging solution for these sinks was typical of many legacy industrial products: multi-material, manually intensive, and far from sustainable. Each sink was packed using a combination of corrugated trays, corner protectors, foam edge profiles, and shrink-wrapped plastic, offering good protection, but at the cost of speed, consistency, and environmental impact.
Pland Stainless wanted a solution that met several key criteria:
- Sustainability: The existing use of foam and plastic did not align with the company’s growing commitment to greener practices.
- Efficiency: The packing process was too time-consuming for the production team, who needed a quicker and simpler method to assemble and secure each unit.
- Storage Compatibility: Before boxing, the sinks are nested together to save on warehouse space, so any new packaging design had to work with this method of storage.
- Cost-effectiveness: Materials needed to be reduced without sacrificing product protection or the visual professionalism of the final package.
- Brand Representation: As a premium manufacturer, the packaging needed to reflect the same high-quality standards Pland Stainless are known for.
It was clear that a bespoke solution would be required—not just a tweak, but a full rethink from the ground up.
Our Design Approach
Having delivered multiple successful packaging projects for Pland Stainless in the past, our team had an in-depth understanding of their operations and expectations. The trust built over years of collaboration gave us the creative freedom to develop a truly innovative approach.
When Ryan Midgley [Purchasing Manager at Pland Stainless] explained the issues with the current packaging, we could see straight away what the core priorities were: sustainability, efficiency, simplicity, and professionalism. We knew this needed to be a clean-sheet design.
— Matt Kay, Head of Design at Greyhound Box
Our in-house design team, led by Matt Kay, got to work on a new concept. Rather than trying to adapt the existing system, we started fresh, replacing multiple components with a single, clever, cardboard-based structure that would offer equal protection with dramatically improved usability.
Key elements of the solution included:
- A completely bespoke tray insert, die-cut on our Baysek machine, designed to cradle the sink securely and allow for safe nesting during storage.
- A standard 0201 outer box, manufactured on our Solarco and Sodeme machines, offering robust protection for transport without excess material or waste.
- A design that requires no plastic or foam, eliminating harmful materials and simplifying end-of-life recycling.
Each component was designed to be fast and intuitive for the packing team to use, speeding up workflow and reducing assembly errors.
Innovating for Sustainability and Speed
What makes this solution special isn’t just that it’s sustainable—it’s that it improves on the performance of the old system in every meaningful way.
By moving to a 100% cardboard solution, we eliminated the need for foam profiles and shrink wrap entirely. These components are difficult to recycle and often end up in landfills, making their removal a major sustainability win.
At the same time, the bespoke tray design meant the sinks could remain nested during storage and be boxed up quickly and securely when needed, reducing packing time and allowing for a smoother, more responsive dispatch process.
This wasn’t about finding an off-the-shelf alternative. Every part of the final solution was created from scratch to suit the way Pland manufactures, stores, and ships their products.
– Matt Kay, Head of Design
The Result: Efficient, Sustainable, and Scalable
The first batch of redesigned packaging was delivered in early 2025 and included over 750 units encompassing the requirements of eight different sink sizes.
The feedback from Pland was overwhelmingly positive. The new system not only met the brief—it exceeded expectations:
- Material use reduced — No more plastic shrink wrap or foam edge protection
- Packing time cut significantly — Simplified tray-and-box structure speeds up workflow
- Improved recyclability — 100% cardboard solution aligns with sustainability goals
- Better space management — Sink units remain nested during storage and are protected prior to boxing
- Professional presentation — A clean, consistent outer design matches Pland’s high standards
We’ve worked with the team at Greyhound Box to improve our packaging for our stainless steel sink units. Our targets were to reduce cost and packing time while increasing the recycled content of our packaging, and preventing damage in transit. We’re thrilled with the outcome and how each of our targets was addressed in detail.
— Ryan Midgley, Purchasing Manager at Pland Stainless
A Platform for Future Innovation
This project represents more than just a packaging upgrade—it’s part of a wider strategic shift for Pland Stainless towards smarter, more sustainable operations.
As our partnership continues, we’re already looking at further packaging lines within their product portfolio. Each brings its own challenges, but also new opportunities to improve sustainability, reduce costs, and enhance product protection.
At Greyhound Box, we’re proud to act not just as a supplier, but as a true packaging partner—developing intelligent, well-engineered solutions that support our clients’ long-term goals.
Could Your Business Benefit from a Bespoke Packaging Review?
Whether you’re aiming to reduce waste, improve your packing line, or align your packaging with modern sustainability standards, our team is here to help.
Let’s rethink your packaging, one box at a time.