SHEARD Packaging operates one of the largest corrugated case manufacturing plants in the UK, producing over 175 million square metres of corrugated board annually.
The firm’s Yorkshire base is home to a Mobile Innovation Centre (MiC), which was showcased at Packaging Innovations & Empack. This brings the full capabilities of the Innovation and Design Centre directly to clients with a design studio, Zünd cutting table, and full testing laboratory.
The factory floor features rows of printers, die cutters, and high-speed case makers operating in synchrony, while the boardroom contains wall visuals that trace the company’s journey from its founding in 1860 to its current status as a fifth-generation, family-owned business.
Owner Roger Whittaker and MD Lee Shackleton have helped propel Sheard Packaging to a turnover of £85 million. The company remains debt-free and independent, reinvesting profits into people, technology, and innovation without the pressures of external shareholders.
Roger said, “At the heart of Sheard Packaging is a simple principle. We look after our people, we look after our customers, and we keep investing in the future of the business. If you get those things right, growth tends to follow naturally. It has never been about chasing numbers. It has always been about building something sustainable that the next generation can be proud of.”
Mezzanine offices overlook the machines and stacks of boxes. Even the staff canteen (The Loft), looks out across the factory floor, a daily reminder that everyone in the business remains closely connected to the craft at its heart.
Steve Carroll, who has been with Sheard Packaging for 47 years, revealed, “I started out making recycled boxes from boards, and now I look after our biggest heritage accounts. I have never wanted to work anywhere else. It really does feel like a family. We eat, sleep, and breathe this business.”
Of 283 staff, 65% have been with the company for more than five years, and new talent continues to join from across the packaging industry and other sectors.
“Every department, every individual contributes to the bigger picture,” added Lee Shackleton. “It is the dedication of our people that allows us to consistently deliver for our customers, even when the market presents hurdles.”
At the heart of the operation is Sheard Packaging’s Innovation and Design Centre (iDC). From new product development to packaging reviews, training days, and value engineering, this custom-built facility allows designers and the new product development team to leverage state-of-the-art tools, including the Zünd digital cutting table and upgraded design software, to bring ideas to life.
Long-standing supplier relationships, FSC-certified materials, and rigorous ISO and BRC standards reinforce Sheard Packaging’s commitment to quality and responsibility. A 12,000-pallet warehouse and a 24/7 nationwide transport network ensure products move from the production line to the retail shelf without interruption.
“My parents were incredibly forward-thinking in their time, introducing recycled board processes long before sustainability became a talking point across the industry,” Roger explained. “They taught us that innovation does not have to be complicated. Often it simply means finding a better way to do the right thing.”
Success has been built steadily over more than 160 years. From producing paper bags and wrappings in 1860, the business has evolved. In recent years, growth has accelerated. Turnover reached £10 million in 2003, £50 million in 2019, and £85 million today, with output nearly doubling in less than five years. The next chapter is already taking shape with the arrival of a third Göpfert rotary die cutter.
“Ambition and growth at Sheard Packaging are never abstract; they are grounded in people, culture, and a heritage stretching back over 160 years,” Roger added. “It’s a legacy that continues to guide every decision, every investment, and every box the company produces.”
Operating as an independent business allows the company to maintain duplicates of critical equipment: two existing Göpfert die cutters, six case makers, two flatbed die cutting lines, and three multi-point specialist gluers (a fourth Bahmüller gluer will arrive this June). Multiple suppliers and sites provide board, stereos, inks and cutting formes. Machinery is interchangeable, so if there is a challenge on a line, work can move to another and maintain both speed and consistency. A maintenance team works seven days a week to keep machines at peak performance.
As Sheard Packaging’s customers have changed, so too has the business. Five years ago trade work accounted for roughly 45% of output. Today, FMCG represents 75%. Each client is supported by a dedicated team comprising an account manager, technical contact, internal sales support, and a CAD designer.
“Seeing both new talent and long-standing team members thrive side by side is incredibly rewarding,” Lee said. “It reminds us that growth is about people, not just numbers. When we invest in our teams, nurture skills, and foster a culture where everyone understands the bigger picture, the benefits extend straight to our clients.”
Behind the scenes, Sheard Packaging is developing SheardSense, a suite of digital value creation tools delivering data-driven insights into packaging performance and supply-chain efficiency. Modules like SupplySense, PackSense, PrintSense and ShelfSense are designed to help clients optimise material usage, pallet configurations, print quality, and shelf presentation. The results are said to be ‘striking’, with clients improving pallet cube utilisation from 22% to 86%, recovering £2.5 million in potential lost sales, and saving tens of thousands in labour costs.
Sustainability is also paramount. Sheard Packaging has achieved Ecovadis Gold and is now targeting Platinum. FSC-certified supply chains are standard, and specialist accreditations, including seafood safety standards, reflect the diversity of the customer base.
The latest project will expand the existing warehouse and utilities to create an additional 3,400 sqm of covered storage and operational space. “We have always believed in reinvesting back into the business,” Roger said. “Whether it’s new machinery, expanding the site, or developing our people, those decisions are about building capability for the future. Being independent gives us the freedom to take that long-term view. We can make decisions today that strengthen the business for the next 10, 20, even 50 years.”
