Case Study: How a UK Retailer Cut Packaging Costs by 25% with Single Wall Boxes
How right-sizing single wall boxes cut packaging costs by 25% for a UK retailer.
The challenge
A UK online retailer used just 3 box sizes for 200+ products. Most items shipped in oversized boxes requiring excessive void fill. Shipping costs were inflated by dimensional weight charges. Void fill consumption was high.
Quick answer
Expanding from 3 to 8 box sizes reduced packaging costs by 25% through right-sizing. Right-sized boxes eliminated void fill for 80% of products. Dimensional weight charges dropped as boxes matched product sizes. Total savings: 15% on box costs (smaller boxes cheaper per unit), 60% on void fill, and 20% on shipping (lower dimensional weight). The 8-size range covered 95% of products with minimal excess space.
The solution
Data-driven size selection.
Covering 95% of products with minimal excess space.
Right-sized boxes hold products without additional fill.
Results
Size: sizing guide or cost reduction.
Lessons
Takeaways0 / 3 checked
Frequently asked questions
25% total packaging cost reduction.
8 sizes covered 95% of products.
Void fill reduction (60%) and shipping cost reduction (20%).
No, analyse your product dimensions and select matching box sizes.
Yes, less wasteful packaging improved satisfaction.
Part of our guide
Product Guide: Single Wall Cardboard Boxes
Expert guides on single wall cardboard boxes for shipping, storage, and e-commerce packaging.
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