10 Essential Packaging Tips for Small Businesses

Cost pressure is real—but downgrading your packaging isn’t the answer. Smart brands know that the real savings come from strategy, not shortcuts. The key is to identify areas where you’re overspending or overdesigning, and then apply targeted fixes that maintain product protection, streamline operations, and preserve your brand’s appearance. Here are six proven ways to lower packaging costs without compromising what matters. Rethink Your Materials, Not Your Message You don’t need premium substrates or specialty coatings for every box. Often, a switch in material spec delivers the same structural integrity at a better price. How to do it: Downgrade from double-wall to single-wall corrugated (if damage rates are low) Replace foam inserts with chipboard or corrugated partitions Use kraft instead of white board for internal packaging where branding isn’t visible Swap soft-touch coatings or laminates for matte aqueous or simpler finishes This preserves your customer experience while reducing waste and cost at the source. Right-Size Every SKU Oversized packaging isn’t just wasteful—it costs more in materials, freight, and void fill. Right-sizing your packaging is one of the fastest ways to cut cost across the board. How to do it: Audit your most frequently shipped SKUs and measure internal void space Consolidate sizes where possible to simplify inventory Switch to smaller mailers or die-cut cartons for low-weight products Use inserts or dividers to stabilize smaller products within tighter boxes This reduces dimensional weight and improves pallet or parcel density. Simplify Your Print Approach You can still brand your packaging without maxing out your budget. Print costs add up when you increase colors, coverage, or setup complexity. How to do it: Use 1-color or 2-color flexographic printing for basic branding Minimize print to one or two sides of the box Print inside the box instead of full exterior coverage for an affordable “wow” moment Skip unnecessary coatings, varnishes, or plate changes Simple, clean branding often looks more professional and is far more cost-effective. Reduce Labor Through Smarter Structures Packaging costs aren’t just in the materials—they’re in the assembly. If your packaging slows down fulfillment, you’re paying for it in time and wages. How to do it: Switch to auto bottom boxes, also called auto-lock, or pre-glued cartons Avoid tray-lid combinations that require excessive folding or taping Use adhesive peel-and-seal mailers to eliminate the need for tape Consider shelf-ready packaging that doubles as display This speeds up your operations and makes training packers easier—especially at scale. Increase Order Efficiency Ordering smarter often reduces cost more than ordering cheaper. How to do it: Increase volume to hit price breaks (especially on custom runs) Bundle packaging components (e.g., boxes + inserts + tape) Set up a stock-and-release program with your supplier Avoid rush jobs by forecasting further ahead A stable order flow lets suppliers optimize production—saving you money on every run. Redesign for Function First Many packaging programs are inherited, not designed. Revisiting your structure with fresh eyes can eliminate unnecessary features and uncover major savings. How to do it: Ask your packaging partner for a design review Remove features that add cost but don’t serve the product Test shipping protection levels—don’t overbuild Design for stackability, shelf fit, or automation to reduce damage and downtime Final Thoughts Lowering packaging costs doesn’t mean watering down your brand or risking product safety. It means being more intentional—about materials, size, structure, and operations. By refining your packaging setup, you can cut cost and improve performance at the same time. Need help lowering your packaging spend?We’ll help you identify where you’re overspending—and design a more efficient, better-performing solution that doesn’t cut corners. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts

When deciding between domestic and overseas packaging production, businesses must weigh key factors like cost, quality, lead times, and logistical complexity. Both options offer distinct advantages and challenges, and your decision will depend on your priorities, such as budget constraints, turnaround needs, and quality expectations. This guide dives into the pros and cons of each option, helping you make an informed choice for your packaging needs. Domestic Packaging Production Advantages Faster Turnaround TimesDomestic manufacturers can deliver products quicker due to shorter shipping distances and streamlined logistics. Superior Quality ControlBeing closer to production facilities allows for easier monitoring and resolving of quality issues. Flexibility and CustomizationProximity enables quicker changes to designs or order specifications, offering greater flexibility for dynamic businesses. Improved CommunicationSharing time zones and language makes collaborating with domestic manufacturers more seamless. Supports Local EconomyChoosing domestic production contributes to job creation and economic growth within the country. Challenges Higher CostsLabor and materials are often more expensive domestically, impacting overall pricing. Limited Sourcing OptionsDepending on the region, local manufacturers may have fewer capabilities or specialized materials. Capacity ConstraintsSmaller manufacturers may struggle to handle large orders or high-volume production needs. Overseas Packaging Production Advantages Lower CostsAccess to cheaper labor and materials overseas often results in significant cost savings, especially for bulk production. Specialized ExpertiseCertain regions excel in specific packaging technologies or materials, offering unique capabilities. High Production CapacityOverseas facilities often have the ability to scale up production to meet large-volume demands. Access to New MarketsProducing overseas can simplify distribution in foreign markets, reducing shipping costs for international customers. Challenges Longer Lead TimesInternational shipping and customs procedures can significantly delay delivery. Quality Control IssuesManaging quality standards remotely is more challenging and requires third-party inspections or trusted partners. Communication BarriersLanguage differences and time zone disparities can complicate coordination. Logistical ComplexitiesCustoms processes, tariffs, and potential shipping delays add layers of complexity. Key Considerations When Choosing Factor Domestic Production Overseas Production Budget Higher costs, better quality. Lower costs, cost-efficient for bulk. Lead Times Shorter, ideal for tight deadlines. Longer, plan for extended shipping. Quality Control Easier to monitor directly. Requires additional oversight. Order Volume Best for small to medium runs. Suitable for large-scale production. Market Goals Supports local markets. May help penetrate foreign markets. *However, please note these oversea production advantages will possibly change with the affects of recent tariffs this year in 2025. When to Choose Domestic Production You need quick turnaround times for seasonal or time-sensitive projects. Quality control and the ability to oversee production are critical. You prioritize supporting the local economy or have a Made in USA branding strategy. When to Choose Overseas Production Cost savings are a top priority, especially for bulk orders. Your project requires specialized materials or technologies not available domestically. You’re looking to expand into new markets and reduce international shipping costs. Conclusion Choosing between domestic and overseas packaging production is about finding the right balance between cost, quality, and logistical considerations. Domestic production offers flexibility and reliability, while overseas production excels in cost efficiency and scalability. Assess your business needs, timeline, and budget to make the best choice for your packaging operations. Need help deciding? Contact us today for expert guidance on sourcing the perfect packaging solution for your business! (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts