Must Have Ideas – Waste Cardboard Conveyor Solution

The Client

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Must Have Ideas is a fast‑growing UK home and lifestyle brand, shipping high volumes of parcels from a large 250,000 sq ft warehouse operating 24/7. With so many outbound orders, the operation generates a continuous stream of cardboard waste from returns, packaging, and over‑boxed goods. The business wanted to improve housekeeping, free up valuable floor space, and streamline its recycling process by automating the movement of cardboard waste from the packing areas to an external compactor/baler.

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The Challenge

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Operating from a new 250,000 sq ft warehouse, Must Have Ideas needed to introduce an efficient waste handling system into an existing layout, without disrupting around‑the‑clock operations. The site’s scale, along with 24/7 working patterns, meant that manual handling of cardboard waste was tying up labour, cluttering aisles and creating safety and housekeeping issues.

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The Solution

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Central Conveyors designed a bespoke conveyor system to automatically transport waste cardboard from inside the warehouse to the external compactor/baler. The system layout was engineered to suit the existing building fabric and workflow, using a combination of robust conveyor sections to collect and elevate material before discharging outdoors into the recycling equipment.

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The conveyor system is sized to comfortably carry up to 1 tonne of cardboard per hour, with features that allow it to handle both bulky, erected cartons and smaller pieces without jamming or excessive spillage. The solution was designed with 24/7 operation in mind, using heavy‑duty components and guarding that support safe, reliable running in a busy warehouse environment.

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The Results

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The new waste cardboard conveyor system has helped Must Have Ideas keep a large, 24/7 warehouse significantly tidier and safer, while improving the efficiency of their recycling process. Manual handling of bulky cardboard has been reduced, floor space is clearer, and the compactor/baler receives a steady feed of material at up to 1 tonne per hour, supporting both operational efficiency and environmental goals.

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The solution provides:

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• Improved housekeeping and safer walkways by removing loose cardboard from the warehouse floor

• Reduced labour and manual handling for waste removal

• A consistent, controllable feed to the external compactor/baler for recycling

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A robust system designed for continuous operation in a high‑volume, 24/7 e‑commerce environment