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What Are the Benefits of Repacking Services in Aviation?

Published date: 03 Jul 2024

Repackaging in the supply chain is a common technique, often used to accommodate changing customer needs and cut down shipping costs.

In this article, we’ll share the benefits of repacking services in aviation, from reducing waste to ensuring easy transportation.

At Aerospheres, we’re pleased to offer repacking services for numerous product lines, including composites, prepregs and chemicals.

To guarantee traceability and safety, our products are labelled and provided with the original certification of origin. Temperature recording can also be provided if necessary. If you’d like to discover more about our expert repacking services, please get in touch. Call us on +44 (0)3333 247 777 and speak to one of our friendly advisors today. 

What is Repackaging?

Repackaging is a process designed to maximise efficiency and reduce costs.

This can involve various activities, such as resizing, reformatting or rebranding items to better suit specific needs or market demands.

In the aviation sector, repackaging takes on diverse forms. From cutting large roles of composite materials into smaller sizes to dry ice shipping, these services aim to make products easier to handle and more cost-effective to transport.

Repackaging products can be beneficial for companies in a variety of ways. For example, the service can increase sales of an existing product by making it more appealing to customers.

Most composites are supplied with large MOQs and long lead times, making it hard to hold the material and meet customer requirements. However, at Aerospheres, we offer smaller-sized roles that are ready to ship, better meeting the expectations of our valued customers and providing a swift, efficient service.

The Benefits of Product Repacking

Some of the key benefits of repacking services include:

Cost Savings

Manufacturers frequently opt for the cheapest packaging when shipping products to distributors. However, this often leads to bulky packages that occupy excessive transportation space.

Larger packaging consumes more space, which increases shipping costs and reduces efficiency. Repacking services optimise the use of shipping space, ensuring products are transported more efficiently, and within a reasonable timeframe.

Enhanced Safety

Safety is crucial in aviation. Repacking services ensure that all products, whether it’s commercial goods or hazardous materials, are packed following strict safety guidelines. 
This includes proper labelling, cushioning and securing of items to prevent damage or accidents during transportation.

Enhanced Customer Satisfaction

By ensuring that goods arrive safely, undamaged and on time, repacking services help build trust, increasing the likelihood of repeat purchases.


Repacking services offer the flexibility to adapt to different needs, whether it’s adjusting to last-minute changes to a customer’s needs or handling oversized or irregularly shaped items. This adaptability is essential for maintaining operational efficiency and meeting diverse client demands.


Sustainability is becoming a crucial consideration in aviation. Repacking services contribute to environmental goals, optimising cargo space and leading to fewer trips.
Additionally, the use of eco-friendly packing materials and methods can further maximise the environmental impact, aligning with broader industry efforts towards sustainable practices.

Repackaging: Product Examples

Repackaging in the aviation maintenance industry often involves converting bulk materials into more convenient forms for use in specific maintenance tasks. Some examples of product repacking in aviation include:


  • Precut Shapes: Bulk rolls of composite prepreg materials are often repackaged into precut shapes or kits that are ready to apply. This minimises waste and speeds up the repair process.
  • Composite Repair Kits: Composite materials, including cloth, resin and hardener are repackaged into repair kits that include all necessary components for a specific type of repair. These kits are commonly tailored to specific aircraft models or repair types.
  • Frozen Prepreg Sheets: Prepreg materials are often stored frozen to extend their shelf life. These materials may be repackaged into smaller, more manageable sheets that can be thawed and used as needed.


  • Precut Film Adhesive Patches: Large rolls of film adhesive are repackaged into precut patches that fit specific repair needs. This allows technicians to quickly apply the adhesive without measuring and cutting from the roll.
  • Adhesive Kits: Adhesives can be repackaged into kits that are designed for specific repairs, ensuring all necessary materials are on hand.
  • Performed Bonding Films: Instead of supplying film adhesives in bulk, they can be repackaged as preformed shapes that match the contours of the parts they are meant to bond. This reduces preparation time and increases precision.


  • Single-Use Cartridges: Sealants that come in bulk containers are repackaged into single-use cartridges or syringes. This makes application easier and ensures the correct amount of sealant is used.
  • Pre-Mixed Sealant Packs: Sealants that require the mixing of components can be repackaged into pre-mixed packs or dual-chamber cartridges that mix the elements as they are dispensed.


  • Consumable Kits: Items such as gloves, brushes and other consumables can be repackaged into kits for specific maintenance tasks, ensuring technicians have all the necessary tools on hand.

Choose Aerospheres

At Aerospheres, our expertise in composites, prepregs and a wide range of chemicals has ensured we provide outstanding repacking services. We are proud to be approved by the OEMs to offer this service and have a dedicated repackaging warehouse.

To find out more about our exceptional product repacking services please get in touch. One of our expert team members will be more than happy to assist you.


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