14/10/2026
Manufacturing Horror Stories, part 1 👻
The ghost costs haunting your margins 💷
This month, we’re having a little Halloween fun with the things that actually keep manufacturers up in the middle of the night…
First up: the costs that come with packing that manufacturers don’t always realise.
Because when everything is done in-house, it’s easy to count the obvious bits - labour, materials, machinery.
But what about the hidden ghost costs like:
👻 The extra space packing takes up that could be used for production.
👻 The time that your production team and managers spend trying to sort it.
👻 The electricity, insurance and servicing costs of every packing machine (not to mention the costs of the machines themselves).
👻 Overtime, agency fees, HR, training time, for taking on temporary people each time you get a surge.
👻 Wrapping, rework, supervision, logistics (and so much more).
And each hidden ghost cost affects your margins..
That’s why keeping packing in-house isn’t always as cheap as it looks on paper.
And it’s also why, on average, Excel saves manufacturers around 30% on overheads compared to doing everything themselves.
Next up in our Manufacturing Horror Stories series:
How to stop your final quarter turning into a packing nightmare 😱…