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9 JANUARY 2023 Â Â Â | Â Â Â Omni Group
Cotton On achieves 56% plastic reduction with Omni’s Perfect Pallet Wrapping Solution
Overview
At Omni Group, we’re proud to work with businesses that are serious about sustainability. Cotton On, one of Australia’s most recognisable retail brands, is a great example of how making smart packaging choices can lead to real environmental and operational gains.
About Cotton On
Cotton On is one of Australia’s most iconic retail brands, known for delivering affordable, on-trend fashion across the globe. Headquartered in Geelong, Victoria, they’ve grown from humble market beginnings to a global network of over 1,200 stores.
The problem
With extensive distribution centres across Australia, Cotton On relied heavily on stretch film to secure pallet loads. However, their existing setup used non-power pre-stretch pallet wrapping machines combined with thicker, lower-performing film, resulting in:
- Excessive stretch wrap consumption per pallet
- High volumes of plastic waste need disposal
- Increased film-related costs across operations
- A growing disconnect with their sustainability objectives.
The Solution
To address the inefficiencies, Cotton On implemented Omni’s Plana Pallet Wrapping Machines paired with our high-performance Elite Stretch Film. This combination delivered an immediate improvement in stretch film performance and significant waste reduction.
The low-profile design of the Plana machine also removed the need for forklift access during loading, allowing Cotton On to create a more efficient, forklift-free wrapping zone, saving valuable warehouse space and improving safety.
The Results
By switching to Omni’s pallet wrapping system, Cotton On achieved:
- 56% reduction in stretch wrap usage.
- Nearly 50% cost savings on stretch film.
- 250% yield increase from Elite Stretch Film.
- Approx. 130 skip bins of plastic saved annually.
- Improved floor space efficiency with forklift-free operation.
This outcome not only reduced operational costs but also helped Cotton On make meaningful progress towards their sustainability goals.
We’re excited to partner with leading industrial packaging supplier Omni Group to roll out the Perfect Pallet Wrapping Solution  at its Australian Distribution Centre in Avalon, Victoria. This innovative and sustainable packaging solution will be a game-changer for the Group, helping to reduce its pallet stretch wrap used in the DC and for our store deliveries by 56 per cent. This move is all part of the Group’s commitment to doing good in reducing our environmental footprint.
Barnaby Gray - Â Head of Central Operations at Cotton On Group
Let’s Talk About
Your Packaging Needs
If you’ve enjoyed reading our case studies and want to see how we can help your business achieve similar results, we’d love to hear from you.

Whether you have a question, need advice, or would like a tailored solution, our team is here to help.
Simply fill in the form and we’ll get back to you as soon as possible.
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9 JANUARY 2023 Â Â Â | Â Â Â Omni Group
Cotton On achieves 56% plastic reduction with Omni’s Perfect Pallet Wrapping Solution
Overview
At Omni Group, we’re proud to work with businesses that are serious about sustainability. Cotton On, one of Australia’s most recognisable retail brands, is a great example of how making smart packaging choices can lead to real environmental and operational gains.About Cotton On
Cotton On is one of Australia’s most iconic retail brands, known for delivering affordable, on-trend fashion across the globe. Headquartered in Geelong, Victoria, they’ve grown from humble market beginnings to a global network of over 1,200 stores.
The problem
With extensive distribution centres across Australia, Cotton On relied heavily on stretch film to secure pallet loads. However, their existing setup used non-power pre-stretch pallet wrapping machines combined with thicker, lower-performing film, resulting in:
- Excessive stretch wrap consumption per pallet
- High volumes of plastic waste need disposal
- Increased film-related costs across operations
- A growing disconnect with their sustainability objectives.
The Solution
To address the inefficiencies, Cotton On implemented Omni’s Plana Pallet Wrapping Machines paired with our high-performance Elite Stretch Film. This combination delivered an immediate improvement in stretch film performance and significant waste reduction.
The low-profile design of the Plana machine also removed the need for forklift access during loading, allowing Cotton On to create a more efficient, forklift-free wrapping zone, saving valuable warehouse space and improving safety.
The Results
By switching to Omni’s pallet wrapping system, Cotton On achieved:
- 56% reduction in stretch wrap usage.
- Nearly 50% cost savings on stretch film.
- 250% yield increase from Elite Stretch Film.
- Approx. 130 skip bins of plastic saved annually.
- Improved floor space efficiency with forklift-free operation.
This outcome not only reduced operational costs but also helped Cotton On make meaningful progress towards their sustainability goals.
We’re excited to partner with leading industrial packaging supplier Omni Group to roll out the Perfect Pallet Wrapping Solution at its Australian Distribution Centre in Avalon, Victoria. This innovative and sustainable packaging solution will be a game-changer for the Group, helping to reduce its pallet stretch wrap used in the DC and for our store deliveries by 56 per cent. This move is all part of the Group’s commitment to doing good in reducing our environmental footprint.
Barnaby Gray - Â Head of Central Operations at Cotton On Group
Let’s Talk About
Your Packaging Needs
If you’ve enjoyed reading our case studies and want to see how we can help your business achieve similar results, we’d love to hear from you.

Whether you have a question, need advice, or would like a tailored solution, our team is here to help.
Simply fill in the form on the right and we’ll get back to you as soon as possible.