Sometimes, making just one small change can make a big difference to a company’s bottom line. That applies to how it packages its products, too. The key is in finding ways to reduce packaging costs without compromising product safety. Here are our top ten tips on how to do it.


Top 10 tips to reduce the cost of your packaging

1. Choose space-efficient materials

2. Review your packing process

3. Consider introducing packaging automation

4. Choose packaging that is quick to assemble

5. Use fewer and better packaging materials

6. Explore bespoke packaging

7. Don’t dismiss secondary packaging

8. Optimise your cube

9. Protect pallets in transit

10. Choose a packaging partner rather than a supplier

Book your free smart audit to find out how you can save on packaging costs!




1. Choose space-efficient materials

Warehouse space is expensive so taking advantage of new technology and materials that are less space hungry can reduce your packaging storage costs. For example, if you are using traditional, bulky void fill materials, consider switching to automated, on-demand air-based or crumpled paper solutions. Not only do they require less storage space, they are also quick and convenient to use.

2. Review your packing process

A review of your entire packing and distribution process, from picking the packaging off the warehouse shelf right through to customer delivery, can reveal bottlenecks and inefficiencies that might be resolved by simply changing the type of box being used or may perhaps require more significant investment such as the introduction of semi- or fully-automated machinery, as the next two points further explore.

3. Consider introducing packaging automation

From case erecting and sealing to pallet strapping and wrapping, there are opportunities to introduce some level of automation at every stage of the packing process. Although new machinery will obviously require financial investment, it can reduce costs longer term through increasing efficiency, freeing regular staff to focus on more productive activities, and reducing reliance on transient staff.

4. Choose packaging that is quick to assemble

Switching from standard boxes and tape to crash-lock bottom boxes can double the speed of the packing process, helping companies realise significant cost benefits. Other innovative options, such as retention packaging, can also cut packing times while at the same time reducing the amount of packaging material required.

5. Use fewer and better packaging materials

Choosing more costly packaging materials can save money in the longer term. That’s because they are typically more effective so less – and fewer kinds of – material is needed in the first place. As well as leading to more economical purchasing, less storage space is required, plus they are often more efficient to use.

6. Explore bespoke packaging

One of the most effective ways to reduce use of packaging materials and create a better customer experience at the same time, is through bespoke packaging design. Because it is designed to fit perfectly around the contents, bespoke packaging can be designed to require less void fill and packaging and, importantly, looks better and offers better product protection.

7. Don’t dismiss secondary packaging

It’s easy to dismiss secondary packaging as an unnecessary expense, but a little outlay here could save pounds down the line if you consider the cost of pallet rejections and freight damage claims. Simple solutions such as using anti-slip and interleaf papers between loads can help prevent slippage and increase pallet stability, while corner and edge protection and cover films provide extra rigidity and protection from dust, dirt and rain.

8. Optimise your cube

Cube optimisation can seem like a jigsaw puzzle, but it’s worth getting it right because it can make a significant difference not only to load stability, but also to transport and distribution costs. The challenge of cube optimisation lies in minimising packaging to get more packages on to a pallet, while at the same time maintaining packaging efficacy. It’s all about finding the right balance between weight, dimension and quality of packaging materials.

9. Protect pallets in transit

While cube optimisation can ensure you fit more packages onto each vehicle, pallets still need protection to prevent movement during transit; products that arrive with the customer damaged eat into your profit margins and reputation. Wrapping pallets in film can improve load integrity, but not all films are equal. Reinforced stretch film may seem expensive, but because it delivers greater strength and yield, less of it is needed; used in conjunction with an automated wrapping machine, it is possible to achieve cost savings of up to 70%.

10. Choose a packaging partner rather than a supplier

When looking to reduce packaging costs it can be tempting to shop around to find the cheapest deal, but any benefits are usually short term. By working instead with a partner who understands packaging and takes the time to understand your business, can help you achieve quality packaging solutions that may cost a little more on the surface, but can bring huge cost-saving benefits to your business.


Book your free smart audit to find out how we can help you innovate!



Why Antalis?

Our experts work with you as partners, taking the time to fully understand your business and its packaging processes. Using this insight, we are able to provide the most cost-effective packaging solution, combining the very best packaging products, ideas and services. Our aim is to help you save on your costs without jeopardising the quality and effectiveness of your packaging.