Cutting Packaging Costs Without Sacrificing Protection
As budgets tighten in 2026, packaging buyers are under pressure to reduce costs without increasing damage rates. Cutting too aggressively can lead to product loss, higher return rates, and frustrated customers. The key is balancing material use, box design, and supply chain efficiency so that savings do not come at the expense of protection.
Where Packaging Costs Add Up
- Oversized boxes: Drive dimensional weight charges.
- Excess materials: Overuse of void fill and inserts.
- Complex SKU mix: Redundant sizes increase inventory costs.
- Inefficient freight: Poor palletization and stacking.
Cost-Saving Strategies That Maintain Protection
- Right-sizing: Match box size to product dimensions to cut DIM charges and material use.
- Optimize corrugated grades: Switch to single- or double-wall where appropriate without compromising strength.
- Consolidate SKUs: Streamline packaging options to reduce inventory overhead.
- Efficient inserts: Replace foam or excess dunnage with engineered corrugated or molded pulp.
- Supplier contracts: Negotiate based on annual volumes, not just peak season orders.
Testing Before Implementing Changes
- Use ASTM and ISTA protocols to ensure changes won’t increase product damage.
- Test for compression, vibration, and drop resistance.
- Run pilot shipments before scaling across the supply chain.
Balancing Sustainability and Cost
Eco-friendly doesn’t have to mean expensive:
- Use recyclable coatings to reduce plastic films.
- Choose corrugated designs that require less material while maintaining stacking strength.
- Highlight sustainable solutions in marketing to offset cost concerns.
Packaging Solutions with Brown Packaging
Brown Packaging helps companies lower costs while protecting products across the supply chain. From SKU rationalization to right-sized corrugated solutions, our team ensures packaging savings don’t compromise performance. Contact us to optimize your packaging program.
References
Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.
ASTM International. (2023). ASTM D4169: Standard Practice for Performance Testing of Shipping Containers and Systems.
Sustainable Packaging Coalition. (2023). Packaging Efficiency and Waste Reduction Report. Retrieved from https://sustainablepackaging.org
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Secondary packaging plays a vital role in the supply chain, influencing marketing, protection, and logistics. It’s an integral component for businesses in various industries. In this blog, we explore the essence of secondary packaging, its significance, various types, applications, and its distinction from primary and tertiary packaging. Understanding Secondary Packaging Secondary packaging encases the primary packaging of a product. It doesn’t come into direct contact with the product but serves as an additional protective layer. This layer of packaging, often seen on store shelves, is crucial in both marketing and safeguarding products during their journey from manufacturer to consumer. The Significance of Secondary Packaging The role of secondary packaging extends beyond mere protection. It is an essential element for branding and marketing, drawing consumer attention with its design and graphics. It also simplifies handling, storage, and transportation of products, particularly in bulk. Additionally, secondary packaging can be a valuable source of product information, such as instructions or ingredients. In today’s environmentally conscious market, eco-friendly secondary packaging options are increasingly important for both brand image and environmental responsibility. Different Types of Secondary Packaging There’s a variety of secondary packaging materials and styles, each suited to different product types and industries. Common forms include boxes and cartons, which offer robust protection and ample branding space. Shrink wrap is great for bundling items like beverages together. Paperboard packaging, often seen in cosmetics and pharmaceuticals, strikes a balance between protection and aesthetic appeal. Plastic cases are another option, offering durability for items like electronics and tools. Applications Across Industries Secondary packaging finds its place in diverse sectors. In the food and beverage industry, it’s crucial for the safe transportation and storage of items. The pharmaceutical industry relies on it for additional protection and information dissemination for medications. In cosmetics and personal care, it enhances brand visibility and safeguards delicate products. For electronics, it provides necessary protection against various environmental factors. Comparing Packaging Levels Secondary packaging differs from primary and tertiary packaging in its focus and function. While primary packaging is in direct contact with the product, such as a beverage bottle, and is mainly concerned with preservation and initial presentation, secondary packaging focuses more on branding, bulk handling, and additional protection. Tertiary packaging, on the other hand, is used for larger-scale handling and transportation, involving items like pallets and crates. Conclusion Secondary packaging is a multifaceted element in product distribution, crucial for protection, presentation, and logistics. It’s not just about safeguarding the product; it’s about enhancing brand value, ensuring product safety, appealing to the target audience, and considering the environmental impact. Thoughtful secondary packaging choices can significantly influence a product’s success in the market. If you are interested in secondary packaging, then partner with Brown Packaging today to get started. (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
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