Packaging protects products during storage, handling and transport, but more packaging does not always provide better protection. Oversized cartons, unnecessary layers and unsuitable materials can increase cost and create avoidable waste throughout the supply chain.
Reducing packaging waste requires a balanced approach. Businesses must use less material without increasing product damage or compromising safety, hygiene and quality.
The most effective improvements usually begin by examining the complete journey from the supplier to the final customer.
Understand where waste is created
A packaging review should document every material used to contain, protect and transport the product.
This may include:
- Primary product packaging
- Inner cartons or dividers
- Protective wrapping and cushioning
- Outer transport cartons
- Pallets and pallet wrapping
- Labels and documentation pouches
- Packaging added during consolidation
The review should also identify why each component is used. Some materials may be essential for product protection, while others may remain because the original design has never been reconsidered.
Right-size cartons and containers
Products packed into oversized cartons require additional cushioning and occupy more transport and storage space. Selecting a carton closer to the product’s actual dimensions can reduce both material use and freight volume.
Businesses should consider the complete pack configuration, including the number of products per inner carton, outer case and pallet.
A more efficient arrangement may allow additional units to fit into a shipment without changing the product itself. This can reduce the number of cartons, pallets or transport movements required.
Packaging should still provide sufficient room for protective material where products are fragile or sensitive.
“Better packaging uses the right amount of material to protect the product, support efficient handling and reduce unnecessary waste.”
Remove unnecessary layers
Packaging designs sometimes include several components performing the same function. A review may reveal duplicated wrapping, inserts or secondary cartons that can be removed.
Changes should be tested before wider implementation. Packaging must continue to protect products through realistic handling and transport conditions.
Trial shipments can help determine whether reduced packaging increases damage. If product condition remains acceptable, the revised design can be introduced more broadly.
Businesses should avoid replacing a small amount of packaging waste with a larger product-waste problem caused by insufficient protection.
Select materials with recovery in mind
Packaging materials should be evaluated for their suitability, availability and ability to be reused or recovered after delivery.
Using fewer material types can make packaging easier to separate. Clear disposal or recycling information may also help customers and receiving teams handle the materials correctly.
Material selection should consider the conditions of the complete supply chain. Packaging may need to withstand moisture, temperature changes, stacking or long-distance transport.
A material with strong environmental credentials provides limited value if it fails during distribution and results in damaged products.
Explore reusable transport packaging
For repeat deliveries between regular locations, reusable crates, bins, pallets or protective covers may reduce dependence on single-use packaging.
A reusable system works best when:
- Delivery routes are predictable
- Packaging can be returned efficiently
- Items can be cleaned and inspected
- Losses can be monitored
- The packaging survives enough cycles to justify its use
The business should define who owns the packaging and who is responsible for collection, cleaning and replacement.
Reusable solutions may be less practical for one-way international shipments unless a reliable return or recovery system exists.
Coordinate changes with suppliers
Packaging is often designed and applied by the supplier, but the buyer may carry much of the cost through freight, storage and disposal.
Buyers should include packaging requirements in product specifications and supplier discussions. This allows both parties to identify opportunities before production begins.
Suppliers may be able to adjust carton sizes, reduce unnecessary components or combine several products within one delivery.
Any change should be documented so that future orders continue using the approved packaging standard.
Improve order and delivery planning
Packaging waste can also result from fragmented purchasing. Several small orders may require more cartons, labels and transport movements than one coordinated shipment.
Consolidating compatible requirements can reduce packaging and freight activity. However, businesses should avoid ordering excessive quantities that may expire, become obsolete or exceed available storage.
The right order frequency balances packaging efficiency with inventory and operational needs.
For multi-location organisations, deliveries can be planned so that products arrive in suitable quantities for each site without being repeatedly repacked during internal distribution.
Monitor product damage
Packaging reduction should be measured alongside product protection. A lower material volume is not a successful outcome if damage and returns increase.
Useful measures may include:
- Packaging weight per product
- Cartons used per order
- Pallet or container utilisation
- Product damage rates
- Returns related to packaging
- Packaging cost
- Quantity of material discarded
These measures help businesses determine whether a change is improving the supply chain as a whole.
Staff and customer feedback can also identify packaging that is difficult to open, separate, store or dispose of.
Set practical improvement priorities
Businesses do not need to redesign every package at once. Initial attention can be directed towards high-volume products and packaging formats that create the most visible waste.
A practical programme may begin with:
- Eliminating one unnecessary component
- Introducing a better-sized carton
- Increasing units per case
- Reducing excessive wrapping
- Testing a reusable container
- Consolidating recurring orders
Successful changes can then be applied to other products or suppliers.
Reducing waste without compromising supply
Packaging reduction is most effective when product protection, logistics and material use are considered together. The objective is not simply to remove packaging, but to design a more efficient system.
GANS South Africa works with clients and suppliers to coordinate product, packaging and delivery requirements. By reviewing specifications, pack quantities and transport conditions, GANS can help identify opportunities to reduce unnecessary material while maintaining product quality.
A structured approach allows businesses to lower packaging waste, improve transport efficiency and create more practical supply arrangements.
