Packaging isn’t just a cost—it’s a performance lever. The right box design can streamline packing, reduce courier fees, and minimise returns. For growing UK businesses, optimising packaging is a direct route to cutting fulfilment costs without compromising on the product protection or customer experience.

1. Reduce Volumetric Shipping Charges

Carriers increasingly charge based on parcel dimensions, not weight. A box that's too large incurs higher fees—even
if the contents are light. Choosing right-sized packaging reduces wasted space and ensures you stay within dimensional thresholds set by couriers such as DPD, Royal Mail, and Evri.

2. Lower Material and Void Fill Usage

Oversized boxes require more filler materials—paper, tissue, or bubble wrap—all of which increase per-order cost. A better-fitting box eliminates unnecessary void fill and creates a more sustainable, cost-efficient unboxing experience.

3. Speed Up Packing and Despatch

Boxes designed for speed—such as crash-lock bottoms or peel-and-seal closures—reduce manual labour time per order. Gaining even 10–20 seconds per order can yield significant cost savings in high-volume environments.

4. Decrease Damage and Returns

Well-fitting boxes reduce product movement in transit. This means fewer damaged goods and lower reverse logistics costs. Customers also associate tight, secure packaging with professionalism and reliability—boosting retention.

5. Optimise Warehouse Space and Inventory

Standardised, stackable packaging takes up less floor and shelf space, allowing better warehouse throughput. It also enables bulk ordering and better forecasting—lowering stockouts and emergency reordering costs.

6. Cut Packaging Waste Disposal Costs

Reducing excess packaging lowers the waste your business generates. This can translate into lower disposal fees or reduced waste collection frequency, especially under recycling contracts.

7. Unipak’s Role in Cost-Efficient Fulfilment

Unipak’s plastic-free boxes are precision-sized and available in both flat-packed and pre-assembled options. We help trade customers balance cost, sustainability, and speed—ensuring your packaging adds value at every stage of fulfilment.


Take Control of Your Fulfilment Costs Today

Contact Unipak’s Fulfilment Team for a no-obligation packaging audit and discover how smarter box choices can streamline your entire operation.

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