Overpacking is a frequent issue in the packaging industry that causes tremendous amounts of waste while lowering your overall production output. This bad habit will cost you each time you use unnecessary materials or take extra time to fill a box on the packaging line. Overpacking can usually be prevented with a few simple changes in your packaging operations. Often the products we ship require far less than what we give them to stay protected during the journey. Here are our 5 tips to avoid overpacking, so you can increase your production and your profits.

Know Your Product Well

How well do you know your product? Fully understanding the type of product you’re shipping and exactly how it functions will allow you to package it correctly. If you don’t know what it needs, how can you deliver that effectively?

You should understand every little detail about your product. From the different materials that went into making it to the complex features it exhibits, you need to know it all. These things will be a major factor in determining the type of packaging it needs to survive the shipping journey. When you don’t know these details, you are more likely to overpack your product.

Make sure you are well-versed on your product before you decide on the packaging. This will allow you to get exactly the level of protection you need without going overboard.

Pick the Right Box Size

Most opportunities for overpacking begin when someone chooses a box that is way too big for the product being shipped. Boxes that are too large require more void fill and cushioning material to keep things secure. This is not necessary in many circumstances and only results in wasted money on excess material.

It’s important to choose a box size that gives a little breathing room for the product without leaving too much space to be filled. This allows you to use only the amount of material you need for protecting the product, whether you choose bubble wrap, foam, or air pillows. By reducing the amount of material used per box, you’re helping your margins and production speed increase over time. It’ll also help reduce shipping costs, as larger boxes typically cost more the ship.

Aim for Lightweight Materials

Overpacked products have increased weight from the extra materials used, which in turn will increase the total cost of shipping. When you avoid overpacking, you help reduce the weight of your finished packages and keep your costs as low as possible.

One simple way to lower weight is to make sure you’re using lightweight materials that provide strong protection. You can often find a lightweight alternative to the materials you’re already using. These will help you reduce the shipping costs while still getting the same level of protection you need. Make sure you have fully optimized your packaging materials to prevent overpacking through weight.

Minimize Everything

One of the easiest ways to avoid overpacking your products is to focus on minimizing everything that goes into the packaging design. This allows you to find the smallest container, the least amount of void fill required, and the lowest weight for affordable shipping costs.

By minimizing the design, you’re not allowing any room for overpacking. This is a great strategy for products that don’t require much to stay protected in transit, but it should be carefully considered for more fragile products. You don’t want to miss an important part of the packaging that will prevent damage, but you should always strive to use exactly what you need and nothing more.

Organize the Box Efficiently

The final tip we have to help you avoid overpacking is to organize multiple parts or products efficiently within your box. Finding a way to have everything fit inside as tightly as possible will help you save space, reduce extra material, and decrease shipping costs.

The more efficient and organized your different components are, the easier it is to use the box space effectively. When things are optimized for their container shape, you’ll be able to fill voids with less product and prevent yourself from using boxes that are way too big. This reduces the weight and the size of your package, which we know are major factors for the cost of shipping.

We hope our 5 tips to avoid overpacking have inspired you to reevaluate your current system to find ways to reduce your overall packaging. By limiting the materials you use, you get only what you need and bring down your packaging costs while increasing your production speed. This allows your business to thrive under larger margins and higher demands with ease. You can follow these simple tips to avoid overpacking your products and keep your operations running smoothly.