How to Reduce Packaging Costs
Practical, proven strategies that can cut your industrial packaging spend by 40-70% without compromising quality or performance.
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Savings buying used vs new
Savings from right-sizing
Avg annual savings per facility
Reuse cycles for quality packaging
Buy Used Instead of New
Save 40-70%Used packaging in good condition performs identically to new at a fraction of the cost. Grade A gaylord boxes, reconditioned IBC totes, and recycled pallets deliver the same function with massive savings.
Key Numbers & Tips
- Grade A used gaylords: $5-12 vs $15-35 new
- Reconditioned IBC totes: $80-150 vs $250-400 new
- Recycled pallets: $4-8 vs $12-25 new
- Used bulk bags: $2-5 vs $8-15 new
Right-Size Your Packaging
Save 15-30%Oversized packaging wastes material, increases shipping costs, and uses more void fill. Choosing the correct size reduces material use, optimizes truck space, and lowers freight charges.
Key Numbers & Tips
- Audit your current packaging sizes vs product dimensions
- Eliminate void fill by matching box size to contents
- Use adjustable-height containers where possible
- Consider half-pallets for smaller loads instead of full-size
Volume Purchasing
Save 10-25%Buying in bulk unlocks tiered pricing that individual purchases cannot match. Even small businesses can access volume discounts by consolidating orders or working with a distributor like PackMesa.
Key Numbers & Tips
- Full truckload orders get the best per-unit pricing
- Consolidate quarterly needs into fewer, larger orders
- Mix product types in a single order to reach volume thresholds
- Ask about standing order agreements for recurring needs
Recycling Programs That Pay You
Save RevenueYour used packaging has value. Instead of paying for disposal, sell your surplus materials to a recycler like PackMesa. Many businesses earn thousands annually from packaging they would otherwise throw away.
Key Numbers & Tips
- Clean gaylord boxes in good condition: $2-6 each
- IBC totes with intact bottles: $30-80 each
- Clean pallets in standard sizes: $2-5 each
- Baled OCC cardboard: market rate per ton
Smart Inventory Management
Save 10-20%Carrying excess packaging inventory ties up capital and warehouse space. Too little causes costly rush orders. The right balance minimizes both waste and emergency spending.
Key Numbers & Tips
- Track usage rates to forecast needs accurately
- Set reorder points based on lead times and consumption
- Rotate stock (first in, first out) to prevent degradation
- Store packaging properly to extend its useful life
Cost Savings in Action
See how businesses like yours have reduced packaging costs with these strategies.
Challenge
Spending $85,000/year on new gaylord boxes for parts storage and shipping.
Solution
Switched to Grade A used gaylords from PackMesa and implemented a return program for their own used boxes.
Result
Reduced annual packaging spend to $32,000 — a 62% savings of $53,000/year.
Challenge
Paying $4,200/month in dumpster fees for used IBC totes and pallets.
Solution
Enrolled in PackMesa recycling program for all used containers and pallets.
Result
Eliminated disposal costs and earned $1,800/month from material sales — a net swing of $6,000/month.
Challenge
Using 3 box sizes for 200+ SKUs, resulting in excessive void fill and oversized shipments.
Solution
Right-sized to 8 box sizes based on product dimension analysis and switched to used corrugated where possible.
Result
Reduced box costs by 28% and shipping costs by 15% through better dimensional weight optimization.
Calculate Your Potential Savings
Use our packaging calculator to estimate how much you could save by switching to used packaging or optimizing your current setup.
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