Improving Efficiency and Sustainability: New Packaging for Mini and Micro Torches

At Wolf Safety, we are always looking for ways to improve not only our products, but how they are delivered and used throughout their lifecycle. Our Mini and Micro Torches have long been trusted for their compact, robust design and reliable performance in demanding environments, and we have recently updated their packaging to improve efficiency across transport and storage, while reducing reliance on plastic and improving packing efficiency.

Old plastic clamshell packaging vs New updated packaging

Previous Packaging

Our plastic clamshell packaging has been a strong and well-established solution, designed to balance durability, presentation and environmental responsibility. It incorporated a minimum of 30% recycled plastic and was fully recyclable, ensuring that material use was considered alongside performance.

However, as requirements across logistics and sustainability have evolved, opportunities were identified to further improve packing efficiency. The clamshell shape, while effective for display, is less space-efficient in bulk volumes, limiting how many units can be transported and stored within a given footprint. This created a clear opportunity to refine the packaging approach while retaining the key strengths of protection and recyclability.

Updated Packaging

The updated packaging builds on this foundation with a move to a cardboard format, reducing reliance on plastic while maintaining the protection required for transport and handling. The design has been carefully developed to balance durability, material use and logistical efficiency.

Old Plastic Clamshell

A key advantage of the new packaging is its regular rectangular cuboid shape. Compared to the clamshell format, this enables more efficient stacking, storage and transportation. Outer cartons now hold 50 units (5 packs of 10), compared to 40 units previously (4 packs of 10), despite the outer carton now being 50 % smaller by volume, allowing better use of space from bulk shipments through to customer delivery.

The more uniform format also improves handling throughout the supply chain, making products easier to store, pick and distribute. In addition, the introduction of barcoding supports faster and more accurate stock control, improving traceability and integration into customer systems.

Careful consideration has been given to the presentation of product information, instructions and graphics on the new packaging, ensuring clarity is maintained for users.

The new packaging keeps the protection of the previous format while improving carton efficiency, handling and traceability.

Updated Packaging - Barcode and Graphics on the packaging

For more information on our Mini and Micro Torches click here