GWP Group

Reduce Packaging Costs

Proven strategies and ideas to help you reduce packaging costs throughout your business

With increasing competition across practically every market sector, plus price pressures affecting everything from raw materials to logistics, companies must look at ways to reduce costs to remain competitive.


Packaging is no exception to this.


As such, many companies view packaging as a necessary evil. A cost that has to be met.


But, your packaging can say a lot about your business. It can carry your branding, offer protection for your products in transit, and it is often the first thing your clients will see when receiving your products.


There is no better way to lose a customer than having your goods arrive damaged.

Reduce packaging costs

Because of this, many successful companies see their packaging as a way of promoting their business, boosting sales and improving efficiency. Companies that recognise the importance of good packaging frequently boast both great brand awareness and satisfied customers.


Many would also argue however that these benefits come at a high cost.


By working alongside GWP Group, the aim will always be to have a direct, positive impact on your business’ profitability. It is a fundamental belief of GWP Group that your packaging should offer all of the benefits you would expect, but at a cost which works for your business.


Please see below for further details of strategies that can reduce packaging costs, regardless of your industry, product or application.

Packaging Rationalisation

Streamlining inventory & economies of scale


One of the most commonly overlooked ways to reduce packaging costs is that of packaging rationalisation. By consolidating similar lines, your business can benefit from reduced costs thanks to leveraging economies of scale and streamlining your inventory.

Minimise packing times

Reduce labour costs whilst improving output


Small gains in productivity can usually make a significant difference to your costs. From reducing spend on labour, being able to manufacture and ship more products and fulfilling more orders, minimising packing times can realise genuine cost advantages.

Reduce shipping costs

Tailored sizes to avoid excess charges and void fill


Whilst usually a marginally higher unit cost, custom sized packaging can soon pay for itself. It eliminates shipping of “empty space”, which is particularly important with the increased use of volumetric shipping. It can also reduce ongoing costs by minimising the cost of void fill.

Eliminate Transit Damage

Minimise return costs, & enhancing customer satisfaction


Transit damage is the hidden cost of your packaging. If items are not protected they can become damaged & unfit for sale. This incurs costs through returns, replacements & “written off stock”. Even worse, it can harm potential repeat business through dissatisfied customers.

Minimise packaging stock

Just In Time supply with a Vendor Managed Inventory (VMI)


Maintaining a large warehouse of packaging stocks can be costly – or can take up space you could be using to expand production. A managed inventory, using just in time deliveries, not only reduces stock holding but also eliminates stock shortages, reduces admin & improves cash flow.

Value engineering packaging

Analysis to ensure your packaging is the optimum spec


Paying too much for packaging? Not sure? Whether you think your packaging is cost effective or not, one thing you can’t be certain of is if your packaging is being manufactured to the optimum specification. A full analysis can often identify a number of cost savings.

Packaging cost reduction with engineered performance

An increasing number of companies are turning to GWP Group to engineer cost savings in their packaging and, ultimately, reduce packaging costs.


And whilst competitive tendering always has its place in driving down cost, even greater gains are to be made through the intelligent use of materials and design.


Through the combined use of specialist software and an in-depth analysis of your current packaging methods, an experienced design team will identify real cost savings through better material selection, design and manufacturing methods.

Free Guide - 17 ways to reduce long term packaging costs

Additional ways to reduce packaging costs

Savings on the cost of packaging are often only one part of the benefits GWP can bring to your business.


For example, savings through the reduction of damage and breakages in transit can easily exceed those to be made on packaging spend alone.


When coupled with a full packaging audit which can also reveal time (and therefore cost) savings in terms of assembly and packing times, GWP are certain you can reduce your packaging costs in at least one, if not many, ways.

How GWP can help reduce your packaging costs

  • Accurate calculation of transit protection / performance
  • Creative design utilising the latest software
  • Minimising of storage and warehouse space / costs
  • Tailored designs to meet each individual clients’ priorities
  • Reduce packing times and enhance productivity
  • Enable cost efficiencies and reduce shipping costs
  • Ultimately, reduce costs without reducing performance

Further Ideas and Strategies

As a starting point, GWP often carry out theoretical testing, which analyses the performance of existing materials used along with the dimensions and style of your existing packaging. Other factors such as the weight of the product, required stacking height, environment and intended use are all also accounted for.


This will provide a strong indication of whether the current material and design is optimised for the application or, in many cases, over-specified.


Whilst over-performing is obviously better than under-performing, our design team can vary the parameters (for example the board and box style) to produce a solution that is well within safe performance levels whilst still allowing us to reduce packaging costs.

Corrugated packaging manufacturer

This can then be further tested through transit trials, ensuring that the theoretical changes made deliver benefits in the real world.


So whilst you see no difference in the performance of your packaging, there is one major difference that you will see – the cost. Over a customer’s entire annual packaging spend, the cost savings can often total tens of thousands of pounds! Plus, of course, there are many other benefits resulting from a project to reduce packaging costs, including cash flow, profit margins and ultimately a healthier bottom line.

Stock Products & Proven Solutions

As well as all of the clever engineering to reduce costs, there are often simpler ways in which you can save money.


Besides the standard range of FEFCO designs GWP offer for example, many years of experience has led to the creation of our own library of cost-effective solutions for an extremely wide spectrum of product types. This is not limited to corrugated cardboard packaging, but also includes Correx, anti-static and even protective flight cases.


Over the last twenty-plus years, these have been continuously developed and refined to save your business money while providing predictable, proven levels of performance.

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Gain a Competitive Advantage… 


Please use the links below to see all the ways that your business could benefit from working alongside GWP Group.

Your Packaging. But Better. 


Whatever packaging you currently use or are looking to source, GWP Group can provide you with a cost effective, successful solution. Please use the links below to find your perfect packaging.

Related Information… 


Please use the links below for further articles and guides covering packaging cost reduction.

Cheap packaging - analysing if it really is cheaper
Watch a video detailing the design process at GWP Packaging
Why packaging costs are rising and how to beat the increases

Free, no obligation advice… 


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Could your business benefit from proven strategies to reduce packaging costs?