Reduce Packaging Costs Without Sacrificing Quality

Reduce Packaging Costs Without Sacrificing Quality

Cut packaging cost by consolidating SKUs (3 box sizes + 2 mailer sizes cover most orders), using ECT-32 for standard shipments and reserving ECT-44+ for fragile or heavy only, and picking cushioning by fragility class.

Quick facts

In-stock SKUs 12
Total options 12
Price from $8.03
Price to $17.00
Average price $12.21
Materials kraft, corrugated, poly, plastic, bubble, paper
Strengths ECT-32
Mil thicknesses 2.5
Pack quantities 25, 100

In-stock options

When to use

  • Fixing a recurring damage, cost, or throughput issue.
  • Spec'ing corrective materials before peak season.

The problem

Packaging spend creeps up when brands over-stock SKU varieties, use premium materials for every order regardless of fragility, or over-spec ECT ratings for their typical shipment weight.

The fix

Consolidate to 2-3 box sizes and 2 mailer sizes. Reserve ECT-44+ for fragile/heavy only. Switch cushioning based on fragility class — not defaulting to bubble wrap for everything.

Alternatives to consider

Frequently asked

How many SKUs should I keep?

3 box sizes and 2 mailer sizes cover ~80% of DTC orders. Fewer SKUs means fewer reorders, less warehouse space, and better per-unit pricing at higher volumes.

Is ECT-32 enough?

For most ecommerce parcels under 25 lb — yes. Over-speccing to ECT-44 for every shipment adds cost without reducing damage on light parcels.

Paper fill or bubble wrap for a mixed operation?

Paper fill as the default — cheaper per cubic foot and recyclable. Reserve bubble wrap for fragile SKUs.