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Designing your packaging to minimise waste is usually the most cost-effective option and the best for the environment. You can do this in a number of ways.

Techniques for reducing production losses include:

• choosing a package shape that minimises waste material
• using computer-aided design/manufacturing (CAD/CAM) systems to plan more efficient packages or component layouts
• using fewer, larger pack sizes instead of a greater number of smaller ones

Techniques for eliminating packaging include:

• reducing packaging to zero
• eliminating unnecessary layers of packaging
• reducing or eliminating the use of adhesives and tapes
• using embossing or in-mould direct printing to avoid using labels

Techniques for reducing packaging voidspace fillers include:

• reducing unnecessary voidspace in containers - for example where there is a cartonboard pack around plastic inner packaging
• avoiding using fillers - such as expanded polystyrene blocks or bubble-wrap
• considering using air as the packing medium to protect fragile products

Techniques for lightweighting and downsizing include:

• eliminating one or more layers to reduce the overall package weight
• replacing blister packs with cardboard packs
• not using plastic film windows
• using double-walled instead of triple-walled corrugated board when strength is needed
• strengthening individual materials to allow you to reduce overall material use
• reducing the average thickness of the packaging where possible
• using CAD/CAM and associated tools
• avoiding putting strength into secondary transit packaging if this is not necessary

Techniques for reducing energy include:

• using low melting-point adhesives
• considering alternative inks, adhesives or coatings
• reducing the sealing temperature for films

Techniques for improving transport efficiency include:

• choosing packaging shapes that will maximise case and pallet utilisation and transport efficiency
• considering using distribution pack sizes that maximise pallet use and transport efficiency
• adapting packaging to slightly underhang if the pallet dimensions are not exact multiples of the pack dimension

See how to design packaging for easy distribution.