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Packaging cost reduction checklist

Fifteen places to look for savings, roughly in order of how often they pay off. Work through it with your last three months of invoices in hand.

Short answer: Changing what you buy (sizes, grades, gauges) usually saves more than negotiating price. Start with box sizes, board grade and stretch film.

Boxes

  1. Right-size your most-shipped boxes. Less air means less board, less void fill and lower dimensional weight. Try our shipping savings calculator.
  2. Check board grade. Are you using double wall or high burst grades where a single wall ECT grade would work? See the box strength chart.
  3. Consolidate sizes. Fewer SKUs mean bigger runs and better pricing.
  4. Consider mailers for soft goods. They can be cheaper than boxes and lighter to ship.
  5. Review printing. Fewer colors or printing on kraft can cut custom box costs. See what custom boxes cost.

Film, tape and fill

  1. Measure stretch film cost per pallet and test thinner or pre-stretched film. See the stretch film gauge guide.
  2. Check stretch wrapper settings. Low pre-stretch settings waste film.
  3. Match tape to conditions. Tape failures in heat and humidity cost far more than the tape.
  4. Reduce void fill by fixing box fit first.

Buying and operations

  1. Consolidate vendors. Packaging, film, tape and janitorial supplies from one source means fewer invoices and less freight.
  2. Stop rush orders. Set reorder points or scheduled deliveries for high-use items.
  3. Buy annual volume with scheduled releases to get volume pricing without storing everything.
  4. Track damage. Damaged shipments are a packaging cost hiding in your returns.
  5. Store packaging properly. Keep boxes dry and off the floor, especially in Florida.
  6. Get a second opinion on specs and pricing at least once a year.

Want us to work through this list for you? Our free packaging audit does exactly that for Tampa Bay businesses.

Frequently asked questions

How can a business reduce packaging costs?

The biggest savings usually come from right-sizing boxes, matching board grade and film gauge to real needs, consolidating SKUs and vendors, and reducing damage. Price negotiation helps, but spec changes typically save more.

How much can a packaging audit save?

It varies widely by company. Some are already well-optimized, while others find meaningful savings in box sizes, film usage or vendor consolidation. The only way to know is to review your actual items and usage.

See where you're overpaying on packaging

Send us your last few packaging invoices. We'll show you where you can save, or tell you you're already in good shape. It's free, and you're under no obligation.