by Richard Rigden, Project Manager and Solutions Consultant, Lucas Systems
It is often said, even the longest of journeys begins with the first step. This is true for many in the warehouse and distribution space when it comes to sustainability. Many organisations, especially small to medium DCs, struggle with just where to begin. I’m here to tell you that it can begin with just one box of paper.
The facts on paper consumption
Worldwide consumption of paper and cardboard has grown steadily over the past 60 years by about 7% year over year, according to a March 2023 report by Statista. This is five times more paper and cardboard than in 1960. In warehouses, while a high percentage of companies have said that investing in technology is important to their future plans, more than 66% of respondents to Lucas Systems recent Voice of the Warehouse Worker survey said that picking, packing and other warehouse processes are still done via paper and pencil.
Warehouses that rely on paper-based picking systems typically use large volumes of paper daily. For instance, a mid-sized warehouse might generate several reams of picking tickets and packing slips every day. Considering that each ream of paper (500 sheets) uses around 6% of a tree, a single warehouse could potentially consume the equivalent of dozens of trees annually just for picking operations.
The impact of going digital
Switching to digital picking systems can drastically reduce this environmental footprint. By replacing paper-based processes with handheld devices, voice-picking systems, or automated guided vehicles (AGVs), warehouses can eliminate the need for printed picking lists and instructions.
For example, a study by the World Resources Institute (WRI) suggests that by digitising processes, companies can reduce paper usage by up to 95%. In a typical warehouse that consumes 1,000 reams of paper annually, this reduction could save nearly 60 trees each year.
According to the operations manager of a Lucas customer in the UK, “The introduction of voice picking to our facility resulted in significant savings in terms of labour and rework activities, while also minimising paper usage, saving 174 trees.”
Poole Bay Holdings, based in Poole, Dorset in the United Kingdom, with 150,000 square feet of warehouse, factory and office space, illustrates another great example of the environmental benefits of moving away from paper-based picking. Poole Bay Holdings implemented Lucas Systems voice-directed, AI-driven solution embodied in Jennifer, the brains, orchestration engine and voice of the solution. The results were immediate and dramatic. With Jennifer, “It was much easier for our pickers to use the system because they receive instructions in their headset, so they don’t have to carry paper with them. They can pick products without the need to shuffle paperwork,” said Wayne Stone, Group Operations and Systems Manager. In terms of sustainability, Poole Bay Holdings had been using approximately 35 cases of paper per week. “That’s dropped down to near zero,” said Wayne. That’s the equivalent to saving 910 trees per year.
Beyond the direct savings in paper, digital systems also improve accuracy and efficiency, reducing the need for rework and the associated additional paper use. They also streamline operations, leading to fewer errors and returns, which further contributes to sustainability.
Broader environmental benefits
The move away from paper doesn’t just reduce paper consumption; it also contributes to lowering the carbon footprint of warehousing operations. Digital systems can decrease energy usage by improving workflow efficiency, thus reducing the time and resources needed to manage orders. Moreover, by decreasing the reliance on physical materials, companies can cut down on the emissions associated with the production, transportation, and disposal of paper products.
The journey to warehouse sustainability doesn’t have to be overwhelming or complex. Starting with simple, tangible changes—like reducing paper use—can set the stage for broader digital transformation. By taking that first step toward digitisation, even small to medium distribution centers can make a significant impact on both their environmental footprint and operational efficiency. Every piece of paper saved is a step closer to a sustainable future, proving that even the smallest actions can lead to profound results on the path to a greener, more efficient warehouse.
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