Packaging is typically the third-largest cost for product-based businesses, after raw materials and labour. Yet most companies have never properly audited their packaging spend — which means there are almost always savings to be found.
Here are proven strategies to reduce your packaging costs without compromising on quality or brand presentation.
1. Right-Size Your Packaging
This is the single biggest opportunity for cost savings. Studies show that the average e-commerce package contains 40% empty space. That wasted space costs you in three ways:
- More material — larger boxes use more cardboard
- More void fill — empty space needs to be filled to prevent product movement
- Higher shipping costs — carriers charge by dimensional weight, not just actual weight
Action step: Measure your top 10 products and ensure each has a box within 20mm of a perfect fit. Even reducing box size by one increment can save 10–15% on material costs.
2. Optimise Your Material Specification
Many businesses over-specify their packaging because they've never questioned the original choice. Ask these questions:
- Do you really need double-wall corrugated, or would single-wall suffice?
- Could you drop from 350gsm card to 300gsm without losing structural integrity?
- Is a full lamination necessary, or would a spot UV or aqueous coating achieve the same effect at lower cost?
- Can you use a standard box size instead of a custom die-cut?
Potential saving: 10–20% on material costs by dropping one grade where appropriate.
3. Consolidate Your SKUs
Every different box size or style you stock has associated costs: tooling, setup, storage, and minimum order quantities. If you have 15 different box sizes, consider whether 8–10 could work instead.
- Can smaller products share a medium-sized box with appropriate void fill?
- Can you standardise to a few core sizes and use inserts for different products?
- Can multi-packs use a single larger box instead of individual packaging?
Potential saving: 15–25% through reduced setup costs, larger quantity pricing on fewer SKUs, and simpler inventory management.
4. Order in Larger Quantities
Packaging printing has significant setup costs (plates, dies, machine calibration). These fixed costs are spread across every unit — so the more you order, the lower the per-unit cost.
| Order Quantity | Typical Per-Unit Cost | Saving vs 250 Units |
|---|---|---|
| 250 units | £3.50 | — |
| 500 units | £2.40 | 31% |
| 1,000 units | £1.80 | 49% |
| 2,500 units | £1.20 | 66% |
| 5,000 units | £0.85 | 76% |
Tip: If cash flow is a concern, negotiate staged deliveries — order 5,000 units but have them delivered in batches of 1,000 over several months.
5. Simplify Your Print Design
More colours = more printing plates = higher costs. Consider these cost-saving design strategies:
- Use fewer colours — a two-colour print on kraft card can look just as premium as a full CMYK print, at half the cost
- Print on coloured stock — instead of printing a background colour (expensive), use naturally coloured card (kraft, black, navy)
- Use flexographic printing for large runs — cheaper per unit than litho or digital
- Reserve premium finishes (foil, spot UV, embossing) for your hero products — not every box needs them
6. Reduce Internal Packaging
Tissue paper, ribbon, stickers, inserts — they add up. Audit your internal packaging and ask:
- Is every element necessary, or is it habit?
- Can you combine elements? (e.g., a printed box interior instead of tissue paper)
- Can you use a single branded sticker instead of a printed insert?
7. Work with the Right Supplier
Not all packaging suppliers are equal. The cheapest quote isn't always the best value. Look for suppliers who:
- Offer free design support — saves you designer fees
- Provide material recommendations — they should proactively suggest cost-saving alternatives
- Have flexible MOQs — important for small and growing businesses
- Offer consistent quality — reprints and customer complaints from poor packaging are expensive
- Provide storage and call-off — order in bulk, take delivery as needed
At QPack, we work with UK businesses to find the right balance between cost, quality, and brand impact. Get a free quote and we'll show you where savings are possible — without cutting corners.