Look Beyond the Unit Cost of Packaging

The lowest-priced packaging product is not always the most cost-effective option. A box may be inexpensive to purchase but require additional void fill, tape and packing time. An oversized parcel may also increase shipping costs or take up more space during storage and transport.

The total operational cost of packaging can include:

• packing time and labour;
• warehouse storage requirements;
• parcel weight and dimensions;
• protective packaging materials;
• product damage and replacement orders;
• customer complaints and returns;
• unnecessary material consumption.

A packaging product should therefore be assessed according to how it performs throughout the complete packing and delivery process, not only by its purchase price.

For example, choosing a postal box that closely matches the dimensions of the product can help reduce empty space, limit the amount of void fill required and create a more efficient parcel. Businesses can select from formats such as postal boxes, ecommerce boxes, large letter boxes and specialist mailers depending on the product and shipping method.

Choose Packaging Around the Product Journey

Effective packaging begins with understanding how a product will move through the supply chain.

A product may be picked from warehouse shelving, carried to a packing station, placed onto a conveyor, transported through a courier network and handled several times before reaching the customer. Each stage can create different packaging requirements.

Businesses should consider:

• the size, shape and weight of the product;
• whether the item is fragile or sensitive to pressure;
• how much movement may occur inside the parcel;
• whether the packaging may be exposed to moisture;
• the expected handling and transport conditions;
• how the customer will open and dispose of the packaging.

Soft goods and lightweight products may be suitable for mailing bags, while fragile goods may require a rigid box with cushioning or dividers.

Bottles, for example, can require specialist bottle packaging to help prevent movement and breakages. Depending on the application, this may include bottle boxes, cardboard dividers, protective sleeving or inflatable bottle packs.

Selecting packaging around the complete product journey helps businesses avoid both under-packaging and unnecessary over-packaging.

Reduce Empty Space and Unnecessary Material

Oversized packaging can create additional costs throughout the operation. Larger boxes require more storage space before use, may need more protective material and can increase the volume of goods being transported.

Reducing empty space can help businesses:

• use less void-fill material;
• create smaller and lighter parcels;
• improve vehicle and pallet utilisation;
• reduce packaging waste;
• present orders more appropriately to customers.

This does not mean choosing the smallest possible box in every case. Products still need enough space for suitable cushioning and protection. The objective is to use packaging that fits the application without creating avoidable empty space.

A well-planned range of box sizes can also make it easier for packing teams to select an appropriate format quickly. This can reduce decision-making at the packing bench and improve consistency between orders.

Reduce Material Without Reducing Product Protection

Reducing packaging material is an important objective for many businesses, but material reduction should not compromise product protection.

If an item arrives damaged, the business may need to process a return, replace the product and ship another order. This can create additional material use, transport activity, labour and cost.

Packaging optimisation is therefore about using the right amount of the right material. The aim is to provide reliable protection without adding unnecessary weight or volume.

Air cushion packaging can support this approach by providing lightweight protection for products during shipping. Air pillows and inflatable films can be used for void fill, wrapping and block-and-brace applications.

Because the film is stored uninflated and converted into cushions when required, air cushion systems can also help reduce storage requirements in busy warehouses and packing areas.

The correct protective material will depend on the product, parcel size and level of protection required. Fragile, heavy or irregularly shaped products may need a different solution from lightweight ecommerce goods.

Make Better Use of Warehouse Space

Packaging occupies valuable warehouse capacity. Bulky consumables can take up racking, restrict movement and require frequent replenishment at packing stations.

Space efficiency should therefore form part of the packaging selection process.

Flat-packed boxes, compact rolls of film and on-demand cushioning systems can help businesses store more packaging in a smaller area. Packaging can then be assembled or produced when required.

This can be particularly valuable for businesses managing a large range of products or seasonal order volumes. Packaging must remain readily available without taking up excessive space that could otherwise be used for sellable stock.

Businesses should also consider where packaging is stored in relation to the packing bench. Frequently used products should be easy for operators to reach, while slower-moving formats can be held elsewhere.

Small improvements to packaging storage and workstation layout can reduce unnecessary movement and help orders pass through the packing process more efficiently.

Improve Packing Speed and Consistency

Packaging should be straightforward for employees to assemble, fill, seal and label. Complicated or poorly matched materials can slow down the process and create inconsistent results.

Businesses can improve packing efficiency by reviewing:

• how quickly boxes can be assembled;
• whether products fit the selected packaging correctly;
• how much tape or void fill operators use;
• whether frequently used materials are within easy reach;
• how consistently parcels are sealed and labelled.

Features such as self-seal closures can help reduce the need for additional tape. Returnable mailing bags may include a second adhesive strip to make customer returns easier, while correctly sized boxes can reduce the time spent adding protective material.

Standardising packaging processes can also help new employees learn packing tasks more quickly. Clear guidance on which packaging format to use for different products can reduce variation and avoid overuse of materials.

Use Packaging Automation Strategically

Packaging machinery can improve productivity, but automation should be introduced to solve a specific operational problem.

This could include:

• increasing packs or pallets processed per hour;
• improving material consistency;
• reducing repetitive manual work;
• supporting higher order volumes;
• improving load stability;
• reducing unnecessary material use.

For example, high-volume operations may benefit from automated or semi-automated pallet wrapping solutions. Machinery can apply stretch film consistently and help businesses control how much material is used on each pallet.

Lower-volume operations may achieve better results by selecting the correct hand pallet wrap and using a suitable dispenser. The right approach depends on throughput, load type, available floor space and the level of consistency required.

Air cushion machines can also produce protective packaging on demand, helping packing teams access void fill without storing large quantities of pre-inflated material.

Before investing in packaging machinery, businesses should define the problem, review current output and calculate the potential operational benefit.

Check Compatibility Across the Packaging Process

Packaging materials increasingly need to work with equipment, printers and automated systems. A product may appear suitable but still create disruption if it is incompatible with the wider operation.

Thermal labels are one example. Businesses may need to consider label dimensions, core size, printer type, perforation and whether a thermal transfer ribbon is required.

Incorrectly specified labels can lead to poor print quality, wasted materials and delays during dispatch. Pallet wrap must also suit the relevant hand dispenser or wrapping machine, while air cushion film should be compatible with the machine being used.

Compatibility should therefore be confirmed before a packaging specification is changed. Warehouse and packing teams can provide useful practical feedback because they work with the materials every day.

Consider the Customer Experience

Packaging is often the first physical interaction an ecommerce customer has with a business. A parcel that arrives safely, is easy to open and contains an appropriate amount of packaging can create a positive impression.

By contrast, damaged products, excessive empty space or difficult-to-open packaging can affect customer satisfaction.

Good packaging should:

• protect the product throughout delivery;
• feel proportionate to the item being shipped;
• be simple for the customer to open;
• provide clear disposal or recycling information where appropriate;
• support straightforward returns when required.

The appearance of a parcel is important, but the primary purpose of packaging remains protection. Decorative presentation should not replace reliable performance.

Measure Packaging Performance

Packaging decisions should be supported by operational data rather than assumptions.

Useful measurements can include:

• packing time per order;
• damage rates by product or packaging type;
• material consumption per parcel or pallet;
• average parcel weight and dimensions;
• packaging cost per shipment;
• customer complaints relating to delivery;
• returns caused by transit damage.

Businesses can use this information to identify where a packaging change may deliver the greatest benefit.

For example, a new box may cost slightly more but reduce void-fill use and packing time. A different pallet wrap may provide the required load stability with less material. A better-matched label may reduce printer interruptions during dispatch.

Testing different packaging formats under normal working conditions can provide a clearer picture of their total operational value.

Treat Packaging as One Connected System

Boxes, mailing bags, protective materials, tape, labels and machinery should not be considered in isolation. Each component affects the wider packing process.

A smaller box may reduce void fill but require a change to packing procedures. A new stretch film may improve material efficiency but need different machine settings. A returnable mailing bag may improve the customer experience but must still provide suitable protection during the original delivery.

Businesses that review packaging as a connected system are better placed to:

• control total packaging costs;
• improve packing productivity;
• reduce product damage;
• use materials more efficiently;
• support future growth;
• deliver a consistent customer experience.

Packaging will always be a necessary consumable, but its value extends far beyond containing a product.

When packaging is selected around the product, warehouse and delivery process, it becomes an important part of the infrastructure supporting an efficient fulfilment operation.

Speak to Kite Packaging about improving your packaging operation.

Frequently Asked Questions

How can packaging improve operational efficiency?

Packaging can improve operational efficiency by reducing packing time, limiting product damage, making better use of warehouse space and helping businesses control parcel weight and shipping costs.

What should a business consider when choosing packaging?

Businesses should consider product size, weight, fragility, shipping method, storage requirements, packing speed and the total cost of the packaging process.

How can businesses reduce packaging waste?

Businesses can reduce packaging waste by using correctly sized formats, avoiding unnecessary empty space and selecting protective materials that provide the required performance without excessive material use.

Can packaging automation reduce costs?

Packaging automation can reduce costs when it improves throughput, material consistency or labour efficiency. The most suitable solution will depend on order volumes and the specific operational problem being addressed.