As e-commerce volumes continue to rise and warehouse operations come under increasing pressure to improve efficiency, packaging is becoming far more strategic than many businesses realise
Packaging plays a direct role in transport efficiency, warehouse productivity, sustainability performance and customer experience. In many cases, the difference between an optimised packaging solution and a “good enough” one can have a measurable impact on operational costs and logistics performance.
That is one of the reasons why Antalis Packaging made its debut appearance at eDelivery Expo 2026 in July, where we showcased our range of e-commerce, fulfilment and logistics packaging solutions designed to help businesses improve packaging performance, reduce waste and lower operational costs.
The Hidden Costs of Poor Packaging Design
Across the e-commerce, retail, automotive and industrial sectors, we see businesses using packaging specifications that have not been reviewed in years. While the packaging may still perform adequately, it is often not optimised for today’s logistics demands.
Oversized cartons, over-specified board grades and inefficient pack designs can erode margins across the supply chain.
A carton that is only slightly oversized may increase corrugated usage, require more void fill and reduce trailer utilisation. Multiply this across thousands of shipments and the impact becomes significant. Businesses can face:
- Increased material consumption
- Higher dimensional weight charges
- Reduced pallet density
- More transport movements
- Higher carbon emissions
- Additional warehouse handling costs
Packaging specifications often evolve reactively as products change, suppliers switch or new SKUs are introduced. Over time, inefficiencies become embedded. This can create avoidable pressure on storage capacity, picking efficiency and transport costs.
Small Changes, Significant Savings
At Antalis Packaging, we work with businesses to review and redesign packaging solutions that deliver measurable operational improvements.
In one recent e-commerce project with a fashion retailer, carton dimensions were redesigned to better match the products being shipped. The changes reduced unused space, improved packing efficiency by 30 per cent and dramatically cut the number of pallet locations required. The project ultimately delivered projected logistics savings of more than £130,000 annually.
In another case, redesigning shipping cartons resulted in a 33 per cent reduction in packaging material, saving 18 tonnes of board annually and significantly reducing associated transport movements. A further project saw a double-wall carton successfully re-engineered into a single-wall solution, reducing paper usage by 35 per cent while increasing pallet efficiency by 40 per cent.
These types of packaging reviews can often be implemented quickly and deliver rapid operational benefits.
Sustainability and Logistics Go Hand in Hand
Sustainability is also becoming a major driver behind packaging optimisation projects.
Reducing corrugated usage, eliminating or reducing void fill and improving trailer fill rates all contribute directly to lower Scope 3 emissions and more sustainable operations.
Importantly, the lightest packaging solution is not always the most sustainable. The most effective solution is one engineered for the application, balancing protection, efficiency and material usage.
To help customers achieve their sustainability goals, we offer Antalis’ Smart Packaging Design and Premium Packaging services, along with protective and corrugated systems, packaging automation technologies and Antalis Packaging’s new carbon calculator, all designed to consider sustainable options, alternatives, or savings in material usage.
When was the last time your packaging was properly reviewed?
Even small changes or board adjustments can deliver significant cumulative benefits. Reviewing packaging now will ensure you are fully optimised ahead of the 2026 peak season. The right box doesn’t just carry your product. It carries your cost structure, your carbon footprint and your customer experience with it.
For more information, visit www.antalis.co.uk/packaging
