WebstaurantStore cuts insulation storage 80% with on‑demand WaveKraft system
WebstaurantStore has recently deployed the WaveKraft On‑Demand Production System on site to replace thick denim insulation, cutting its insulation storage needs by 80%. The system produces packaging from paper rolls at rates of up to 2,000 insulation panels or 1,200 protective mailers per hour, with a roll change taking about three minutes.
Because paper rolls are dense while finished packaging is mostly air, one truckload of rolls yields the equivalent of ten truckloads of finished WaveKraft insulation products. This allows warehouses to reclaim floor space, eliminate the middle‑mile leg of shipments, and reduce the number of SKUs they must stock. At a facility handling 5,000 orders a day, eliminating the box‑assembly step alone saves roughly 125 labor hours each day. The WaveKraft Padded Mailer, made from the same system, provides up to 45% better shock absorption than a plastic bubble mailer and carries the Widely Recyclable label with 25% recycled content.
“Switching to WaveKraft transformed our operations. In addition to the immediate transformation the equipment provided, it has matched our ROI expectations in the first quarter of operations,” Distribution Center General Manager, Cold Chain, WebstaurantStore said.
Facilities previously ordered packaging based on forecasts made weeks ahead, so by the time material arrived demand had often shifted. Peak season arrived early, specifications changed, or promotions pulled demand forward, leaving dock doors clogged with trucks of consumable packaging instead of sellable goods. High‑volume operations paid for that mismatch with wasted receiving time and excess storage of pre‑made packaging.
What we know
WaveKraft On‑Demand produces 2,000 insulation panels per hour or 1,200 protective mailers per hour depending on configuration.
The move reduced insulation storage needs by 80%.
At a facility shipping 5,000 orders a day, eliminating box assembly alone returns roughly 125 labor hours daily.
It passes testing against ISTA® 6 Amazon Overbox protocols and delivers up to 45% better shock absorption than a plastic bubble mailer.
It carries the Widely Recyclable label from How2Recycle® and uses paper sourced from SFI‑certified mills, including 25% recycled content.