From its humble beginnings in the mid-20th century, modern flat pack furniture has become a global phenomenon. It has revolutionised the way we buy and transport furniture, to the point where pretty much all of us have a piece of flat pack furniture at work or at home. And this is thanks in large part to retailers like IKEA, who made the concept work so well for manufacturers, retailers and for customers.
The success of flat pack furniture hinges on its design, but also on its packaging. Flat pack furniture can be complex, and made up of many parts: boards, panels, hardware, and more. Making sure it all arrives intact and undamaged is a major challenge, especially when low shipping weight and compact dimensions are a priority.
And so, many manufacturers choose layflat tubing (LFT) as part of their packaging systems. It’s a versatile packaging solution that has made flat pack furniture possible. So, let’s explore the history and benefits of flat pack furniture, the role of layflat tubing, and how LFT fits seamlessly into a broader packaging system.
The rise of flat pack furniture
Carpenters have been making furniture that’s easy to disassemble for centuries. Long before cars and lorries, furniture had to be carried in some way, and breaking it down was the only option most of the time. Then, sometime in the early 1900s, mail order flat pack furniture made its appearance. Most efforts were short lived – until the 1950s, when a certain Swedish furniture maker made a push for flat packs.
IKEA
It’s impossible to tell the story of flat pack furniture without IKEA, the Swedish furniture giant that refined the concept.
So the story goes, IKEA technician (and employee number 4 at the company) Gillis Lundgren collected a new table. The table wouldn’t fit in his car – so he had to saw the legs off it to fit it in, and then repair it at home. He came up with a new concept for a furniture kit; simple, flat panels that could turn into working pieces of furniture; like the now infamous Billy bookcase which he designed.
He took the idea to IKEA’s founder, Ingvar Kamprad, and IKEA started selling their stylised, super simple flat pack furniture in 1956.
This innovation made it easier for customers to transport furniture themselves – and it slashed costs across the board. Transportation, manufacturing, storage… Everything was maximised.
But the journey from factory to living room is fraught with hazards, and packaging had to be designed just as well as the furniture itself. Flat pack components, often made of particleboard and MDF, are susceptible to moisture damage and denting during transit.
Traditional cardboard boxes have long been the go-to solution, with paper inlays and extremely tight tolerances – but moisture protection has always been an issue. This is why layflat tubing for flat pack furniture packaging has steadily been rising.
Layflat tubing: a shield for flat pack furniture
Polythene layflat tubing is flexible, durable, and lightweight. It’s usually delivered rolled onto a core, and can be easily cut and sealed to create custom sized protective sleeves. This adaptability makes it an ideal solution for flat pack furniture, where components may vary in size on only one axis.
One of the standout features of polythene is just how good a barrier it is. Unlike cardboard, which can be prone to moisture damage, layflat tubing is water-resistant – and while it’s soft, it’s also highly durable. Layflat tubing acts as a cushion, absorbing shocks and preventing scratches, dents, and cracks. This makes it particularly effective in shielding flat pack components in transit.
Humidity, rain, and dust can wreak havoc on materials like MDF, but layflat tubing’s barrier properties keep everything dry and clean. That’s helpful in warehouses and during shipping, too – where furniture parts can be exposed to dirt, grease, and other contaminants. It also keeps any metal parts coated in grease away from absorbent woods and boards in the package.
Custom dimensions
Polythene layflat tubing is so versatile; it can be easily cut and sealed to create custom sized packaging, and a perfect fit for every component. This customisation enhances protection and minimises waste, as the material can be tailored precisely to the requirements of each piece.
For example, a flat pack wardrobe might include panels of varying sizes, with shelves and hardware. Layflat tubing can be used to create individual sleeves for each component (or group of components). This can be hard to achieve with cardboard alone, and achieves additional shielding for sensitive parts.
Layflat tubing as part of a packaging mix
While layflat tubing offers significant advantages, it is not always intended to replace everything. Instead, it complements existing packaging systems, enhancing their effectiveness. Cardboard remains the preferred choice for outer packaging due to its rigidity, and stackability – but used in combination with layflat tubing, the result is a packaging system that offers the best possible outcomes.
Space-saving efficiency
Layflat tubing aligns perfectly with the space-saving principles of flat pack furniture. Unlike bulky packaging materials, layflat tubing is lightweight and compact, adding minimal mass to the overall package. This reduces shipping costs, cuts the space needed for packaging stock, and makes it easier for customers to transport their furniture.
Sustainability
Despite the pushback against plastic packaging, polythene is often the most sustainable choice when used responsibly and correctly.
Read more – Bangladesh: The First Country to Ban Polythene, 23 Years On
Polythene requires way fewer resources to make than card and paper, and is on balance less polluting to waterways than paper mills. And even though it’s derived from the oil and gas sector, it’s less CO2-producing throughout its lifetime, reducing the shipping weight of everything from flat pack furniture, to the essential foods and medical supplies we need to live.
Most importantly, it’s reusable and recyclable. The natural strength of polythene makes it a prime candidate for reusable, circular packaging initiatives – and even in the worst case of recycling outcomes, it still retains all the properties that make it such an attractive packaging material.
For flat pack furniture packaging, recycled blend layflat tubing can be used. It’s just as effective as virgin material, often at a lower cost as it helps companies pay less tax – and it benefits the environment, too!
Order custom layflat tubing for your flat packed products
Talk to the polythene experts at NPF Packaging, and design your own custom layflat tubing – with recycled blends and durable designs for circular use. Enquire online to get a quote now, or call us on 01773 820415 to find out more about our manufacturing and design process.