How to Reduce Packaging Waste in Manufacturing: 6 Proven Strategies

Introduction

Manufacturers face constant pressure to protect products without overspending on packaging. Oversized boxes drive up DIM shipping costs, require unnecessary filler materials, and take up more storage space — all of which quietly eat into margins long before a product ever reaches a customer.

The good news? Reducing packaging waste isn’t just a sustainability win — it’s a long-term cost saver. It also improves productivity across the manufacturing process by reducing the number of touchpoints and eliminating common types of packaging waste like oversized boxes, void fill, and excess stock. While some changes may require small upfront adjustments, right-sized packaging, reduced filler, and smarter shipping strategies quickly lead to lower DIM costs, less material waste, free up storage, and improved efficiency. Below are six proven strategies manufacturers can use to cut waste, control costs, and meet growing sustainability expectations.

Why Packaging Waste Is a Real Business Problem

Addressing packaging waste reduction and adopting sustainable packaging practices in the manufacturing process can significantly reduce disposal costs, improve supply chain performance, and reduce what ultimately becomes landfill waste. By prioritizing packaging optimization, recyclable materials, and more efficient waste handling, manufacturers can support a circular economy while improving operational efficiency and reducing environmental pollution caused by poor packaging choices.

The Hidden Costs of Overpackaging

You think you are saving money buying stock sizes although oversized boxes and unnecessary materials lead to:

• Higher DIM shipping fees
• Increased material costs (fillers, etc)
• More damaged goods during transit
• Excess inventory sitting unused

Packaging waste quietly erodes margins.

Customers Notice Excess Packaging

Today’s customers expect efficient, sustainable packaging. Excess waste can lead to negative reviews, lower brand affinity, and lost repeat business — especially for DTC, subscriptions, and ecommerce brands where the unboxing experience matters.

6 Proven Strategies to Reduce Packaging Waste

Learning how to reduce packaging waste in manufacturing starts with a clear plan: prioritize source reduction by right-sizing and redesigning product packaging, switch to eco-friendly materials, and explore reusable packaging systems for inbound and outbound logistics. Combine packaging optimization with supplier collaboration to standardize components and eliminate extra materials, and invest in automation that reduces human error and overpacking. Finally, track your progress with packaging-related KPIs and support zero-waste goals by partnering with recycling processors and implementing take-back programs that help reduce the amount of waste generated during the packaging process.

1. Use Right-Sized Packaging

Design boxes that fit your products precisely. Right-sized packaging reduces material use, lowers shipping costs, and minimizes damage risk — all while improving sustainability. Your customers notice when packaging is intentional, not oversized.

For example, a candle brand adjusted their packaging to better match the size and weight of their products. By switching to boxes that fit each candle more securely, they reduced dimensional weight (DIM) charges, minimized product movement during transit, and significantly lowered damage rates. Similar right-sizing strategies are used across industries like cosmetics, subscription kits, and specialty foods — where snug, well-designed packaging protects products, cuts waste, and improves the customer experience from delivery to unboxing.

2. Switch to Digital Printing with No Minimums

Traditional print runs often force manufacturers to over-order. Digital printing allows for:

• On-demand production
• Smaller batch sizes
• Reduced excess inventory

DIYpack’s no-MOQ model helps eliminate waste before it starts.

For example, cosmetic brands launching seasonal collections use digital printing with no minimums to order smaller packaging runs for each SKU instead of committing to a large offset print run. Traditional offset printing often requires large amounts of packaging to be ordered at once, increasing the risk of waste. This allowed them to test new designs, avoid excess inventory, and update packaging as products evolved — without wasting printed boxes. Similar approaches are used by subscription box companies, specialty food brands, and beverage startups that rely on frequent design updates or limited releases, making digital printing a practical way to stay agile while reducing packaging waste.

3. Consolidate SKUs Using Modular Box Designs

Create packaging that works across multiple product variations instead of designing a different box for every SKU. Start by identifying your top-selling products and common order combinations. By standardizing packaging around similar product sizes, you can reduce the number of box sizes you stock, streamline fulfillment, and minimize wasted material.

Modular box designs help maintain product protection while cutting down on excess packaging and unnecessary shipping boxes — making them a smarter, more sustainable choice for manufacturers.

For example, an electronics accessories brand consolidated its packaging by using a small set of modular box sizes for chargers, cables, and bundled kits. Instead of stocking separate boxes for each SKU, they standardized packaging around core dimensions, reducing storage needs and simplifying fulfillment. This also improves inventory management by reducing complexity in storage and fulfillment workflows. Apparel brands often take a similar approach by using one or two box sizes for folded garments and multi-item orders, while health and wellness companies package supplements, bottles, and starter kits in shared modular boxes. Across industries, this strategy reduces excess packaging, limits unused inventory, and creates a more streamlined, sustainable operation.

4. Reduce Void Fill with Smarter Box Design

Instead of relying on non-eco-friendly fillers like plastic air pillows, foam peanuts, or excessive paper void fill, design boxes that fit products more precisely. Right-sized corrugated packaging minimizes empty space, reduces material waste, and improves shipping efficiency — which also enhances the unboxing experience. Research and industry reporting show that optimized packaging reduces waste and carbon emissions while boosting customer satisfaction, because consumers increasingly dislike oversized boxes filled with excess filler material.

5. Choose Sustainable Materials That Perform

Recycled corrugate offers impressive strength without unnecessary weight. DIYpack uses up to 99% post-consumer recycled content, proving that durability and sustainability can coexist. Selecting the right packaging material is critical — it affects recyclability, product protection, and brand perception. Our corrugated boxes are 100% curbside recyclable, making them a strong example of a closed-loop system — where old boxes are recycled into new ones instead of ending up as waste.

Corrugated boxes made in the U.S. are also highly reusable. DIYpack carefully selects the correct flute sizes for each box to ensure strength, protection, and reusability. Many customers reuse their boxes for storage or returns before recycling them, extending the life of the packaging and reducing overall waste even further.

6. Streamline Procurement by Partnering Directly with a Manufacturer

Working directly with a packaging manufacturer — and cutting out the middleman — helps reduce supply chain inefficiencies, shorten lead times, and protect your margins. Direct partnerships often mean better visibility into production, fewer handoffs, and less waste throughout the process.

When evaluating a partner, look for manufacturers that own their equipment, handle production in-house, and ship directly from their facilities. This level of control can lead to more consistent quality, faster turnaround times, and a more efficient, sustainable packaging operation overall. DIYpack checks all of these boxes — and as part of Bay Cities Packaging, partners also gain access to expanded resources as they grow, including structural engineers, graphic designers, and packaging experts who can help evolve and optimize our partners packaging strategy over time.

Packaging Formats That Help Manufacturers Waste Less

• Mailer Boxes: Efficient, right-sized, lightweight corrugated formats ideal e-commerce shipping like jewelry, cosmetics (small), apparel, books, small electronics, home goods, and subscription boxes for fitting products in snug and securely
• Shipping Boxes: Custom dimensions reduce excess material and enhance protection for small to large items
• Square Tube & Triangle Tube Boxes: Perfect for long products offering superior stacking, better branding space, and protection compared to round tubes
• Literature Mailers: Designed for flat products — ideal for shipping or carry out

Explore custom corrugated boxes to reduce waste across your operation.

How DIYpack Helps Manufacturers Package Smarter

DIYpack supports lean manufacturing and sustainability goals with:

• No minimum order quantities
• Right-sized custom designs
• Local pickup options to reduce shipping emissions
• 5–7 business day turnaround for just-in-time needs
• Recyclable materials and water-based inks

Less waste. More flexibility.

Conclusion – Reduce Waste, Keep Quality, and Protect Your Brand

Reducing packaging waste doesn’t require a complete overhaul — just smarter decisions at every stage. With right-sized designs, sustainable materials, and flexible ordering, working directly with manufacturers like DIYpack can help lower costs while still meeting customer expectations.

Low-cost, stock box sizes may seem like a savings upfront, but they often lead to excess material, higher shipping costs, and unnecessary waste. By weighing the strategies above, you can find more efficient packaging solutions that benefit both your business and the environment.

Visit DIYpack.com to explore packaging solutions built for efficiency, quality, and sustainability.