The failure mode in a packaging changeover is trying to replace everything at once. Four materials change, four packing procedures change, and the packing team is retrained on all of them in the same week, usually just before a peak.

Format by format is easier and nearly always faster overall. Replace bubble wrap with honeycomb first, because it is the most visible change and the easiest to demonstrate. Add fanfold or crinkle for void fill next, once the bench has learned one new material. Leave the hardest case, usually a foam-protected item, until last.

Each step needs one machine, and the machines can be introduced separately because they share the same input roll. That also means the roll store and the handling arrangement only have to be built once.

Run the two systems in parallel for a period rather than switching on a date. The old material stays on the bench until the new one has survived a real peak, which is the only test that matters and the only one nobody schedules.