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Packaging cost savings

Same product. Same protection. Lower cost.

Packaging costs you three ways: the material, the labor to pack it, and the freight to ship it. We find money in all three. Most of what we change, your customer never sees.

Optimized furniture packaging secured on a pallet for shipment

Does this sound like you?

"We've used the same box for ten years. Nobody's looked at it since."
"Our supplier says the price went up. We have no way to check."
"We're shipping a lot of air."
"Packing takes too long and we can't find people to do it."
"We don't know what good pricing even looks like."
You don't need a packaging engineer on staff to fix this. You need someone to look.

Three places your money goes

Most people only look at the price of the box. That's one third of the cost.

A stacked box, for material cost

Material

What the box, bag, film, and label cost to buy. Often the wrong grade, the wrong size, or more parts than the job needs.

Where we find money
  • A lighter grade that still protects
  • Fewer separate parts
  • Right sized to reduce material usage
A worker, for labor cost

Labor

What it costs in time to pack it. Every extra fold, tape strip, and hand step is money, and it repeats on every single order.

Where we find money
  • Fewer steps per package
  • Designs that go together faster
  • Simple automation where volume justifies it
A delivery truck, for freight cost

Freight

What it costs to move it. Carriers charge for size as well as weight, so a half-empty box costs real money on every shipment.

Where we find money
  • Right-size the box to the product
  • Fit more units on a pallet
  • Cut the wasted air
Most projects find money in two or three of these at once. That's why the total is usually bigger than people expect.

How we work

Four steps. Start at the beginning, or jump in where you already are.

First, which one are you?

"I already know what needs fixing"

Plenty of people land here with the problem already named: a box that's too big, a line that's too slow, a price that jumped last quarter. Tell us what it is and we can start at step 3.

→ starts at step 3
"I want an expert assessment"

You know the number is too high, but not where it's coming from. That's exactly what step 2 is for. We look across your packaging, your process, and your freight, and tell you where the money actually is.

→ starts at step 2
Most people are somewhere in between. The call sorts it out in about ten minutes.
Free call
30 minutes

1. Free call

Tell us what you ship and roughly what you spend on packaging. We tell you whether there's likely money here, about how much, and which step you should start at.

Opportunity identification
1 to 2 weeks

2. Opportunity identification

We analyze your current packaging, how you pack it, and how it moves through your supply chain. Then we rank the best opportunities and put a size on each one. You see how much is on the table before you commit to anything.

Teardown and redesign
2 to 3 weeks

3. Teardown and redesign

We take the packaging apart piece by piece and put a cost on every layer. Then our engineers redesign it. You get three to five real options, each with the price difference next to it.

Validate and implement
3 to 4 months

4. Validate and implement

We test the new design to be sure it still protects the product. We build the financial case so finance can sign off. Then we write the specs, get supplier quotes, and help you make the switch without stopping your shipping.

You can stop after any step. And if you already know what needs fixing, we can start at step 3.

What you get

OPPORTUNITY ANALYSIS Where your money goes Cost per unit vs category benchmark ITEM YOURS BENCH Δ Corrugated cases$0.84$0.68+24%HIGH Flexible pouches$0.31$0.29+7%LOW Rigid clamshells$1.12$0.86+30%HIGH Labels & inserts$0.06$0.05+18%MEDIUM BIGGEST OPPORTUNITIES 1Rigid clamshells$40–60K/yr 2Corrugated cases$25–35K/yr 3Labels and inserts$8–12K/yr Figures shown are sample data. Prepared by BoldtSmith Packaging SAMPLE

Your opportunity analysis

Where your money is going across material, labor, and freight, with every opportunity ranked and sized. You find out what is worth chasing and what isn't.

YOUR OPTIONS Priced alternatives $0.79per unitRight-sizeSame boardsaves ~$18K $0.71per unitRecommendedLighter gradesaves ~$34K $0.64per unitRedesignNew structuresaves ~$52K RECOMMENDED YOUR CURRENT COST $0.84per unit Recommended saves ~$34K/yr Sample pricing shown. Prepared by BoldtSmith Packaging SAMPLE

Your options

Three to five real alternatives with a price on each one, so you're choosing between numbers instead of guessing.

IMPLEMENTED Approved & rolled out APPROVED SPEC Board grade32 ECT → 29 ECT Inner dims305 × 228 × 152 mm Supplier quote$0.71 / unit APPROVED BOLDTSMITH ROLLOUT Specsapproved Supplierquoted Toolingin progress SwitchoverQ3 Sample rollout shown. Prepared by BoldtSmith Packaging SAMPLE

Implemented solutions

Tested designs, approved specs, supplier quotes, and the switchover done. Savings that show up in what you actually pay, not just in a report.

Why us and not a broker

A delivery driver reviewing an order on a tablet in a loaded van

We count freight and labor, not just material

A cheaper box that ships worse or takes longer to pack isn't cheaper. We add up all three costs before we call something a saving.

Two workers taping and inspecting shipping boxes

We don't sell you the packaging

We are engineers, not a supplier or a broker. We make nothing on what you buy, so the cheapest honest answer is the one we give you.

A consultant shaking hands with warehouse staff

The first step is small

You see a real number in a week, for a small fixed fee, before anyone asks you for a big commitment. If the number isn't good, you stop.

Is this you?

A good fit if…

  • You spend $250,000 a year or more on packaging
  • You ship a physical product
  • You have more than a handful of packaging items
  • Nobody on your team designs packaging

Probably not a fit if…

  • You have one product at very low volume
  • You ran a formal packaging cost program in the last 18 months
  • Your packaging is a legal or regulatory requirement you can't change

Questions people ask

Will my packaging look cheaper?

Not unless you want it to. Most of the savings are in things your customer never sees: the grade of board, how it stacks on a pallet, how many separate parts there are. We flag anything that would change the look before we recommend it.

What do you need from us?

A list of your packaging items, twelve months of what you spent, your current supplier prices, and freight information if you have it. If you're missing some of that, we work with what you have and tell you how it affects the accuracy.

Do we have to change suppliers?

No. The biggest savings usually come from changing the design, not the vendor. If a supplier is genuinely overcharging, we'll show you the proof and let you decide.

How much can we save?

It depends mostly on how long it's been since anyone looked. We give you an honest range after the first week, with a confidence level attached, so you can decide whether it's worth going further.

We already use a broker. Is this different?

Yes. Brokers work on price. We work on design, spec, and how the package moves — which is where most of the money is hiding. The two don't conflict.

Will this hurt our sustainability goals?

Usually the opposite. Less material and less wasted space means less to buy and less to ship. When there's a real trade-off, we put both numbers in front of you.

Find out what you're overpaying. It takes 30 minutes.

Tell us what you ship and what you spend. We'll tell you whether there's real money here and where it's most likely hiding.

Reduce-Packaging-Costs-Form
Free. No sales pitch. You'll speak to someone who does this work.
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