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Packaging moves products safely through supply chains, but it also carries an environmental cost that many organizations underestimate. For B2B brands, packaging decisions affect shipping efficiency, regulatory compliance, and sustainability reporting.
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A closer look at what typically ends up inside a package reveals where waste accumulates and where meaningful reductions are possible.
Primary Packaging Materials
Primary packaging is the layer that directly contains the product. Common materials include corrugated cardboard, plastic films, molded pulp, glass, and metal. In B2B shipping, corrugated cardboard dominates due to its strength and recyclability.
Waste often appears when boxes are oversized or reinforced beyond actual load requirements. Excess material increases disposal volume and shipping weight, which adds cost across distribution networks.
Plastic films and wraps are frequently used for moisture protection or bundling. While lightweight, they are less likely to be recycled in commercial settings. When these materials are used without a clear functional need, they contribute disproportionately to landfill waste.
Protective Fill and Cushioning
Void fill is one of the largest contributors to unnecessary packaging waste. Bubble wrap, foam peanuts, air pillows, and paper fill are intended to prevent damage during transit. Problems arise when fill is added by habit rather than necessity. Overpacking often reflects a mismatch between product size and box dimensions.
Paper-based fill offers easier recycling, but volume matters. Even recyclable materials create waste if used excessively. Selecting box sizes that closely match product dimensions reduces the need for filler altogether.
Secondary and Tertiary Packaging
Secondary packaging groups products for handling or branding, while tertiary packaging supports palletized shipping. Shrink wrap, stretch film, strapping, and pallets fall into this category. Stretch film is a major waste stream in warehouses, particularly when pallets are wrapped multiple times for stability.
Wood pallets are reusable, but damaged pallets are frequently discarded. Poor pallet quality or inconsistent sizing leads to higher turnover and disposal rates. Standardizing pallet systems can significantly reduce material loss over time.
Labels, Inserts, and Documentation
Printed materials are often overlooked in waste assessments. Packing slips, instruction manuals, promotional inserts, and return labels add up across high-volume shipments. Many of these materials duplicate information already available digitally. Reducing paper inserts or consolidating documentation into a single sheet lowers waste without disrupting operations.
Adhesive labels also matter. Non-recyclable adhesives can contaminate cardboard recycling streams, making otherwise recyclable boxes unusable.
Purchasing and Design Decisions
Waste is influenced long before a package is assembled. Procurement strategies that emphasize standardization help control material use. Companies that buy boxes in bulk often gain access to consistent sizing and material specifications, which supports better packing discipline. Design choices that prioritize right-sized packaging and material compatibility make downstream recycling more effective.
Auditing packaging components across suppliers reveals inconsistencies that drive waste. Aligning packaging standards across product lines simplifies training, reduces errors, and lowers disposal volume.
Packaging waste is rarely caused by a single material. It is the result of cumulative decisions across design, procurement, and fulfillment. By examining each component inside the package, B2B organizations can identify practical opportunities to reduce waste, control costs, and support sustainability goals without disrupting supply chain performance. Look over the accompanying resource for more information.
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