There are three universal truths that now apply to the packaging industry:
There is a solution: one of the most effective ways to combat the costs, meet the targets and please the customers is to switch to made-to-size cardboard boxes. By right-sizing packaging to match products, businesses can optimise shipping costs, significantly reduce waste, improve protection and customer satisfaction, without compromising efficiency.
In this article, we will explore the ways in which custom packaging delivers both economic and environmental benefits and why, for increasing numbers of ecommerce businesses, it’s becoming a core part of modern fulfilment strategies.
Made-to-size cardboard boxes are specifically designed and produced to fit products precisely. Instead of having to choose from a limited range of box dimensions, bespoke packaging matches the exact product measurements. This means products don’t have to be forced into mailers or envelopes that are just a little too tight or left to jiggle around in cartons or boxes too roomy.
This approach is a win-win for businesses. Firstly, it enables them to eliminate unnecessary, empty space inside their packaging resulting in a more efficient, professional and cost-effective shipping solution that aligns with both operational and sustainability goals. Secondly, it takes the mental gymnastics away from the packing station: packers know what they need to use, can pack properly, swiftly and dispatch faster and frustration free.
Traditional packaging has its part to play in ecommerce. However, one of its biggest inefficiencies (and customers’ bugbears) is excessive void fill: bubble wrap, air pillows, crumpled paper, polystyrene peanuts, tissue paper and so on and so forth.
Made-to-size boxes, on the other hand, often have a feature which dramatically reduces the need for void fill, rendering it obsolete entirely: variable height creases. This nifty adaptation (check out one example, here) allows a single box footprint to be adjusted in height and folded down to the exact depth required. This results in less cardboard used per shipment and lower packaging material costs as well as the reduced reliance on the aforementioned protective fillers.
Cutting down on both box material and void fill means that any business, big or small, can significantly reduce waste whilst improving their packing efficiency.
Trips to the Post Office will have informed even those of us not up, close and personal with the packaging industry that couriers increasingly base their prices on dimensions rather than actual weight. Oversized boxes can and do push shipments into higher pricing brands, even when contents are lightweight.
If a cardboard box has been made-to-size however, its dimensions will be as compact as possible and higher charges avoided. Additionally, warehouse and transport space can be better utilised and more parcels fitted per pallet or vehicle as well.
Over time, even for businesses that aren't high-volume shippers, these savings add up. Custom packaging is a powerful lever for controlling logistics costs.
Empty space inside a box doesn’t just waste money, it increases the risk of damage. Products that can shift about during transit – even when buffeted by void fill - are far more likely to suffer impact damage. Dealing with returns and customer complaints is annoying, costly, time consuming and damaging to a business’s brand.
Custom packaging provides a snug fit that stabilises items during shipping without the need for excess cushioning. With less or no movement inside the box, products are better protected resulting in fewer damaged goods, reduced return and replacement costs and improved customer satisfaction.
Sustainability is no longer optional. Businesses are under pressure from all angles: customers, regulators and stakeholders all want to reduce their environmental footprint. Eco-friendly boxes made to the correct size are a simple but highly effective step.
Right-sized packaging supports sustainability by using fewer raw materials, reducing packaging waste at the customer’s end, lowering transport emissions through more efficient loads and supporting recyclable and responsibly sourced cardboard.
Switching to made-to-size cardboard boxes is another way in which companies can demonstrate a genuine commitment to sustainable packaging without sacrificing performance or cost efficiency.
As businesses grow, fulfilment operations must scale too. The trick is enabling this to happen without it becoming prohibitively complex or costly. This is where custom packaging solutions come in: they can be designed to integrate seamlessly into an established automated or semi-automated packing process and they also have other benefits:
Rather than stocking dozens of box sizes, companies can streamline inventory while still delivering perfectly sized packaging for every order.
Made-to-size cardboard boxes offer businesses a clear advantage in today’s competitive logistics landscape and address the issues we face in the packaging industry face today.
Custom packaging delivers measurable value across the supply chain by reducing waste, lowering shipping costs and improving protection. They are a labour-saving, sustainable solution for businesses looking to cut costs and improve their environmental impact. Right-sized, eco-friendly boxes aren’t just a packaging upgrade: they’re a far smarter way to ship.
Let us guide you towards your packaging goals so you can grow your business, delight your customers AND save on shipping. We work directly with the UK’s largest and most capable packaging manufacturers to offer you unparalleled quality whilst saving you money. We can offer you a unified, tailored solution whatever sector you’re in, whatever direction you need to go in. Call us and let’s Talk Made-To-Size Packaging today.
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