How to Standardise Packer Usage Across Your Installation Team

Why Standardising Packer Usage Matters

Companies with multiple installers often face one major problem:
every installer uses packers differently.

Some over-pack, some under-pack, some only use certain sizes, and others improvise with whatever is nearby.
This inconsistency causes:

• Uneven window and door alignment
• Frequent callbacks
• Snagging issues on large sites
• Difficulty training new installers
• Wasted materials and time
• Lack of quality control

By standardising packer usage, companies can improve efficiency, consistency, and installation quality across the entire team — while dramatically reducing long-term costs.

The First Step: Use the Same Type of Packers Across the Company

Many issues arise because teams mix:

• Timber shims
• Cardboard shims
• Leftover materials
• Random packers from different suppliers

This causes inconsistent thicknesses and unpredictable performance.

A professional company should decide on one uniform packer range, such as:

• Colour-coded plastic flat packers
• Wedge packers for adjustments
• Bridge packers for screw clearances

Using the same branded packs ensures identical thicknesses and predictable behaviour across every installation.

Create a Standard Thickness Guide for Your Team

Installers should know exactly which packer thickness to use in each scenario.

A simple thickness guide helps:

• 1 mm → micro adjustments
• 2 mm → minor levelling
• 3 mm → general support and common spacing
• 4 mm → levelling uneven sills
• 5 mm → toe-and-heel work
• 6 mm+ → doors and heavy units

This chart can be added to:

• Van checklists
• Site posters
• Installer handbooks
• WhatsApp groups
• Training documents

Ensuring every installer follows the same rules improves consistency.

Standardise Toe-and-Heel Procedures

One of the biggest sources of variation is how installers toe-and-heel.

If one installer places packers incorrectly, the sash will drop.
If another over-packs, the frame may bow.

Create a standard procedure:

For side-hung windows:

• Bottom hinge corner → pack under the glass
• Top lock corner → pack on the side

For top-hung windows:

• Toe-and-heel both bottom corners

All installers must follow this exact pattern to ensure identical results.

Use Colour-Coded Packers to Reduce Errors

Colour coding is the fastest way to keep teams consistent.

Installers instantly recognise:

• 3 mm → white
• 4 mm → blue
• 5 mm → red

Colour coding means:

• Less time measuring
• Fewer mistakes
• Faster training
• Uniform packing across jobs

Site managers can visually check packer thickness at a glance.

Train Every Installer on Correct Packer Placement

Incorrect placement causes:

• Dropping
• Bowing
• Seal failure
• Misaligned locks

A company-wide standard should include:

• Where to place bottom setting blocks
• Where to position toe-and-heel packers
• Where to avoid packing (drainage areas)
• How to place side stabilising packers

Conduct a short internal training session so all installers follow the same rules.

Keep the Same Bulk Stock in Every Van

Many companies fail because different installers carry different equipment.
One installer may have the perfect packers — another might run out mid-job.

Standardise van stock:

• Bulk 3 mm packers
• Bulk 4 mm packers
• Bulk 5 mm packers
• Mixed sets for unusual gaps
• Bridge packers
• Wedge packers

This ensures every installer always has the correct packer for every job.

Create a Packer Usage Checklist for Each Job Type

A simple checklist removes guesswork and promotes consistency.

For uPVC windows:

• 2 bottom setting blocks
• Toe-and-heel diagonal corners
• 1–2 side stabilisers

For doors:

• More toe-and-heel points
• Larger packers (6–10 mm)
• Multiple frame alignment packers

For renovation or old properties:

• Wedge packers for uneven surfaces
• More mixed pack use

These checklists ensure identical installation quality across all teams and sites.

Reduce Improvisation and Non-Approved Materials

Standardisation fails if installers:

• Grab cardboard
• Split wood shims
• Fold plastic waste into spacers
• Use silicone blobs instead of packers

Make it part of your company policy:

No improvised shims allowed. Pack with approved plastic packers only.

This ensures long-term structural reliability and protects your reputation.

Why Standardisation Leads to Bulk Purchasing

Once your company standardises packer usage, you’ll naturally require:

• Larger quantities
• Consistent restocking
• Bulk orders for core sizes
• Mixed sets for flexibility

This lowers your cost per packer and ensures uninterrupted workflow.

Bulk purchasing becomes the logical and cost-effective outcome.

Final Thoughts

Standardising packer usage transforms installation quality across a company.
It ensures:

• Faster installations
• Fewer mistakes
• Less training time
• Reduced snag lists
• Fewer callbacks
• Improved margins

For best results, every installation team should carry:

• Bulk flat packers (3mm, 4mm, 5mm)
• Bridge packers
• Wedge packers
• Mixed sets for adjustments