As e-commerce volumes rise and warehouses come under increasing pressure to improve efficiency, packaging is becoming more strategic than many businesses realise, writes Jason Poxon, Head of Design at Antalis Packaging.
In many cases, the difference between an optimised packaging solution and a “good enough” one can have a measurable impact on operational costs and performance.
That is one of the reasons why Antalis Packaging will be at eDelivery Expo 2026; from 30 June to 2 July at the NEC Birmingham (Stand 9020)
We will showcase our range of e-commerce, fulfilment, and logistics packaging designed to improve 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 packaging specifications that have not been reviewed in years. While the packaging may still perform, it is often not optimised for today’s logistics demands.
Oversized cartons, over-specified board grades and inefficient pack designs can erode margins.
A carton that is 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 weight charges
•Reduced pallet density
•More transport
•Higher carbon emissions
•Additional handling costs
Packaging requirements often change as products or suppliers change. Inefficiencies become embedded. This creates pressure on storage, picking and transport costs.
Small Changes, Significant Savings
Antalis Packaging works with businesses to review and redesign packaging that delivers measurable operational improvements.
In one project with a fashion retailer, carton dimensions were redesigned to better match the products shipped. The changes reduced unused space, improved packing efficiency by 30% and cut the number of pallet locations required, delivering projected logistics savings of more than £130,000 annually.
In another case, redesigning shipping cartons resulted in a 33% reduction in material, saving 18 tonnes of board annually and reducing transport movements. A further project saw a double-wall carton successfully re-engineered into a single-wall solution, reducing paper usage by 35% while increasing pallet efficiency by 40%.
Similar packaging reviews can be implemented quickly and deliver rapid benefits.
Sustainability and Logistics
Sustainability is also becoming a major driver behind optimisation projects. Reducing corrugated usage, eliminating or reducing void fill all contribute 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, protection, efficiency and material usage.
Solutions at eDelivery Expo
The Antalis stand will showcase a range of technologies and consultancy-led services for e-commerce, fulfilment and logistics environments.
Solutions on display will include: Smart Packaging Design and Services, premium packaging, protective and corrugated systems, packaging automation technologies, Ranpak systems, including FillPak Mini, as well as our new carbon calculator.
When was the last time your packaging was reviewed?
Even small changes can deliver significant cumulative benefits. Reviewing packaging now will ensure you are fully optimised ahead of the 2026 peak season.
In Summary:
The right box doesn’t just carry your product.
It carries your cost structure, your carbon footprint and your customer experience.
Antalis Packaging can help you with reviews, redesigns, and recommendations.
Visit www.antalis.co.uk/packaging or contact the team: 0370 241 1466.
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