Rethinking the Full Box: How Corrugated Trays and Shrink Bundling Reduce Cost and Waste

Traditional corrugated RSC cases (full boxes) have long been the standard for shipping and shelf display. By completely enclosing products on all six sides, RSC cases provide strong protection and ample surface area for branding and labeling. However, this approach also requires a substantial amount of material and adds significant weight and bulk to every pack.

Today, many manufacturers are re-evaluating whether a full corrugated box is truly necessary, especially for products that are inherently durable, such as canned goods or plastic bottles. In many cases, the answer is no. This is where corrugated tray and shrink-film bundling offers a smarter alternative.

As part of nVenia’s portfolio of packaging automation solutions, the ARPAC Brand specializes in high-performance shrink bundling and tray packaging systems designed to support this shift away from traditional full-case packaging.

The Cost and Sustainability Advantage

Replacing full corrugated cases with tray-and-shrink solutions can significantly reduce packaging costs, often lowering material costs by 20 to 30 percent and significantly reducing shipping or freight costs. At the same time, material usage and packaging waste are dramatically reduced.

Beyond cost savings, tray and shrink bundling delivers meaningful sustainability benefits, including:
• Reduced corrugated and paperboard consumption
• Lower overall package weight and transportation emissions
• Improved recyclability through material reduction
• Enhanced shelf-ready presentation that can elevate brand appeal

ARPAC, an nVenia brand, supplies complete solutions for this approach, including integrated tray packers and shrink bundling systems such as the ARPAC 45TW, ARPAC 65TW, and ARPAC BPTW Series. These systems are designed to handle a wide range of product types and production speeds while delivering consistent, high-quality bundles.

To support the corrugated side of the system, ARPAC also offers a range of tray forming and packing solutions, including the ARPAC EL Series, ARPAC TrayStar, and ARPAC PC Series. These systems are designed to run a wide variety of corrugate styles and product configurations including case and tray, with speeds ranging from 10 to 60 trays per minute, making them ideal for both moderate and high-volume production environments.

Corrugated Tray with Dual-Roll Shrink Bundling (Transport-Focused)

In this configuration, products such as a 12-pack of cans or bottles are placed on a partial corrugated tray. A dual-roll shrink bundler then applies clear plastic film, typically LDPE shrink film, from two rolls that meet and seal around the package.

The result is a tight, secure bundle that holds the products firmly on the tray while maintaining full product visibility. Depending on the machine and settings, the ends of the package may be fully enclosed or feature small openings often called bull’s-eye holes.

ARPAC’s dual-roll shrink bundling systems, including models like the 65TW, are engineered for high-throughput, transport-ready applications. They provide the strength required for palletizing and distribution and are widely used for warehouse and store-aisle packs such as water bottles, canned foods, and other high-volume consumer goods.

This solution delivers reliable protection during transport while using far less corrugated material than a full box.

Corrugated Tray with Single-Roll Bundling and Printed Film (Shelf-Ready Packs)

For retail-facing applications, corrugated trays can also be paired with single-roll shrink bundling using pre-printed film. In this method, a printed, print-registered shrink film wraps around the tray and products, typically with a bottom overlap seal, creating a visually striking, shelf-ready multipack.

Because the film is precisely registered, high-quality graphics such as brand logos, product imagery, barcodes, and promotional messaging align perfectly on the finished package. This allows manufacturers to achieve bold branding and strong shelf impact without the cost of a fully printed corrugated box.

ARPAC’s single-roll bundling solutions, including systems within the BPTW Series, are built for these applications, delivering precise film handling, consistent sealing, and the flexibility to run a variety of retail multipack formats.

Single-roll shrink bundling is commonly used for:
• Branded trays of soda or soup cans
• Bottled beverages wrapped in printed shrink film
• Display-ready multipacks that go straight from pallet to shelf

The finished package meets retailer requirements for shelf-ready packaging. It is easy to stock, easy to shop, and visually appealing while maintaining the logistical efficiency of shrink bundling.

A Partner from Packaging to the Dock Door

With nVenia and its ARPAC Brand, manufacturers gain more than just equipment. They gain a partner focused on total system performance. From tray packing and shrink bundling to integrated end-of-line solutions, nVenia delivers systems designed to improve efficiency, reduce material usage, and support long-term operational goals.

Backed by a U.S.-based team of sales, engineering, and service professionals, nVenia works closely with customers to design and implement fully integrated packaging lines from primary packaging through secondary packaging and all the way to the dock door.

The result is a streamlined, cost-effective system tailored to your product, production goals, and sustainability objectives.