PERS: The Perfect Packaging Cost Reduction Solution For Your Business

Whatever your business sells, packaging is always a crucial step in giving your customers a memorable experience. Yet it is easy for companies to overlook the role of a streamlined packaging procedure in keeping production costs low whilst still delivering a high-quality product.  

Luckily, Challenge Packaging’s in-house Packaging Expense Reduction Service (PERS) can supply your business with all the guidance you need to optimise your cost reduction techiniques in packaging, from the warehouse to your customers’ homes.  

Streamline your packaging processes through our three-step packaging cost reduction assessment

The PERS process is designed to give you an informed packaging cost reduction assessment in three simple steps: 

1. Review your packaging costs 

The first step towards improving your packaging efficiency is to assess your current packaging procedure. An expert member of our team will visit your business’s site to audit the packaging you use and how you use it, identifying areas for improvement. 

2. Taking steps to minimise excess costs 

Using our learnings from the site visit, we produce a customised strategy to help your business reduce packaging costs. We leave no stone unturned in streamlining your packaging processes. Whether it is minimising waste in your supply chain, optimising packing efficiency or ensuring shipping costs are kept at a minimum, our audit gives you comprehensive and actionable recommendations for making positive changes to your processes. 

3. Save money on packaging 

Finally, we instigate the changes, and you save money on packaging costs! 

How to reduce packaging costs in the warehouse 

The journey towards producing beautiful packaging without inflating costs starts with optimising your procedures when manufacturing your boxes. Here’s a rundown of how to reduce the cost of packaging in the warehouse.

Get staff training right  

Ensuring your staff are fully trained in using machinery safely and minimising waste is vital to reducing packaging costs.

Properly trained staff will more effectively use resources and package products, reducing the likelihood of damage in transit.

By investing time into building a team that consistently delivers high-quality packaging that you are proud to send to customers, your packaging costs will be significantly streamlined in the long term.

Organise your warehouse  

No matter how well trained your team is, unless your warehouse is organised, allowing them to work efficiently, your costs will remain high.

Zoning your warehouse properly, mapping different areas for materials, and minimising the need for unnecessary movement around the warehouse during production are all examples of ways you can save time and reduce your packaging costs.

Additionally, properly monitoring administration around returns, label printing, and supply of materials is crucial to organising a smoothly functioning packaging operation.

Explore options for automated procedures 

It will never be possible to eliminate manual work in packaging. Still, businesses can reduce packaging production costs by investing in machinery to do tricky jobs quickly with less expenditure on labour. Assembling cartons, taping boxes and organising stuffing materials are all time-consuming tasks which a machine can perform at a fraction of the cost of human labour.

Regular maintenance of machinery is another way to reduce packaging costs by ensuring your automated procedures operate smoothly.

Using machinery also means the packaging is not susceptible to human error in construction, giving you a consistent product, which helps build brand reliability.

Finally, automated operations can reduce packaging costs by avoiding injuries in the workplace. By eliminating dangerous mechanised procedures, you will foster a safer working environment and reduce your susceptibility to workplace injury claims.

Use appropriate materials  

There are a wide range of materials you could use for packaging and choosing wisely will pay dividends when it comes to your bottom line of packaging costs.

Buying correctly fitting boxes will save you money on stuffing materials,dividers and fillers and produce a smartly designed box that will impress on opening. Stuffing materials are extra costs for vacant space. Investing in custom boxes which eliminate the space and deliver savings on unnecessary materials is a great way to reduce packaging costs.

Striking a balance between reducing the variety of box sizes you use and packaging products in inappropriate boxes is crucial to saving costs on packaging.

Organise your products according to their size, and explore options for custom-fitted boxes to minimise the risk of transport damage and create a personalised impression on customers upon reception.

Reducing packaging costs in shipping 

Once your packages are ready to leave the warehouse, you need to build a strategy for minimising the cost of shipping.

Nowadays, couriers cost shipping by both the weight of a package and the size of the box. This is another reason choosing the right boxes is essential for reducing packaging costs. If you are shipping light items in oversized packages, your business will feel the impact of extra shipping costs.

Managing the weight of each package by eliminating redundant materials in packaging is simultaneously a great way of reducing packaging costs and minimising waste.

As well as this, we recommend establishing a good relationship with your courier and inquiring about bespoke options for saving money on your account with them. By negotiating, you can make their lives easier and reduce the costs that come with shipping.

How to reduce your packaging costs today with PERS 

Reducing packaging costs is vital for creating a sustainable business. To find out more about PERS, get in touch by calling 01825 748800 or email

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