During the development and manufacture of our packaging products, we consider the potential environmental impact of the materials we employ throughout.
Key considerations integral to this approach are:
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Environmental policy
Foam plastics
High performance materials, tested in accordance with harmonised European Standards, are at the core of our packaging product range. We extensively research materials and select only those which are manufactured without the use of either CFC or HCFC blowing agents, that have a zero ODP, are fully recyclable, and where possible contain at least 30% recycled content.
The majority of the waste generated within our manufacturing processes is also ultimately recycled.
Adhesives
As part of our manufacturing processes, we use water-based and hot-melt adhesives exclusively to minimise the damage to the environment. We do not use any solvent based adhesives.
Packaging
Where possible we try to minimise the environmental impact of the packaging we use by supplying our finished products in lightweight recycled polythene bags. If corrugated boxes are required, these are manufactured from recycled cardboard and are fully biodegradable.
Our Sustainable Process
Here at Excel Packaging, we are committed to sustainability by incorporating the cradle-to-cradle approach into our packaging solutions. Here is how we do it.
Raw Material Delivery: We take delivery of huge blocks of raw material.
Design & Manufacture: We design and manufacture your packaging solutions with precision, utilising our many years of experience.
Waste Recycling: All waste produced during the manufacturing process is recycled.
Recreation: Recycled materials are turned back into chip foam or used as insulation.
Design process
Excel employs it's own proven 'ten point' packaging design process to assist in the development of the most appropriate packaging solution for your application.
A brief overview of this procedure is detailed below:
1
Determine the distribution environment
Singularly placed or palletised multiples?
UK or export?
Own transport or carrier?
2
Define product fragility and damage criteria
Is the product particularly susceptible to damage?
What damage tolerance level is acceptable?
3
Ascertain the product volume and value
What quantity of product is to be considered?
Is the product high or low in value?
4
Select the most appropriate materials
What type and grade of material(s) is required or the most appropriate to use?
5
Design the proposed packaging solution
Develop the most appropriate and cost efficient pack design and calculate cost.
6
Obtain outline approval for the pack design and costs submitted
Does the proposed pack design and cost meet with the custumer's outline approval?
7
Produce a prototype sample
Does the proposed pack design meet with the custumer's approval?
What will the lead time be?
8
Verify pack performance
Assessment by customer or on the customer's behalf.
Assessment to a recognised industry standard (e.g. ISTA) if required.
9
Receive the customer's approval and confirmation of the order
Schedule the order into our production planning system and advise the delivery date.
10
Fulfill the customer's order
Deliver the product in good order and appropriately packaged.
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Excel Packaging was founded by Graham Woolley in January 1994. Initially based in Uxbridge, Middlesex, the company relocated in 2000 to its current premises in Rickmansworth, Hertfordshire. In its early years, Excel Packaging also manufactured specialist products for the warm-water underfloor heating industry. In 2012, this division was separated into a standalone business—Epic Insulation Ltd—which operated from its own premises on the same industrial estate. Graham sold Epic Insulation in November 2024 and is now fully focused on driving the continued development of Excel Packaging.
In 2018, Excel Packaging expanded by acquiring a neighbouring unit to its original factory. This additional space allowed the company to invest in a large-format CNC routing, knifing, and creasing table, significantly broadening the range of materials it could process. Following the sale of Epic Insulation at the end of 2024, further major investment has been made in 2025 with the opening of a new facility (Unit 3). This expansion increased both production space and conversion capabilities, while also strengthening staffing levels and upgrading machinery. Graham’s ongoing commitment to reinvesting in the business ensures that Excel Packaging will continue to deliver the outstanding service and support our customers have come to expect.