In e-commerce, packaging impacts shipment protection, shipping cost, packing time and the amount of waste your customer has to deal with. That’s why sustainable packaging doesn’t mean “less material at all costs” – it means a better fit between the product, the packaging design and your packing process.
From a corrugated board manufacturer’s perspective, the most effective optimization usually starts with reducing empty space, simplifying the construction and standardizing pack-out. Only then does it make sense to fine-tune grammage, flute type or the way the product is stabilized.
What does sustainable e-commerce packaging mean in practice?
A sustainable shipping pack should combine three elements: minimal material use, shipment safety and easy recycling. In practice, it means the packaging is “fit for purpose” – no overkill, but also no avoidable damage risk in sortation.
At the manufacturer level, material reduction should be data-driven: correct board selection, structural design and testing. See how we work in Research and Technology (R&D) and how we build our ESG approach in practice in Sustainable development.
Why does void fill grow in parcels – and why is it a problem?
The most common reason is too few carton sizes or a lack of standard pack-out rules. When the product “floats” inside the box, packers add void fill: paper, air pillows or film. The result is a larger parcel, higher transport cost and more waste for the customer.
Importantly, a lot of void fill doesn’t automatically increase protection. If the box design and corrugated board parameters are selected incorrectly, damage will return with the first overload in transit.
How to reduce void fill in parcels? 7 proven methods
You can implement the steps below in stages – from quick process tweaks to a full packaging redesign.
1) Right-sizing: match the box to the product and basket profile
This is the simplest way to reduce empty space at the source. Instead of filling “air”, you design box formats around real shipments.
In practice: take your TOP 20 SKUs and most common baskets, then design 5–8 box formats instead of 2–3. Many companies see results after the first pilot.
If you want to approach it systematically, see our service: Packaging audit for e-commerce.
2) Replace loose fill with corrugated inserts and stabilization
Loose void fill can shift and compact. Corrugated stabilization works differently: it immobilizes the product so it can’t gain speed and hit the walls.
Options include spacer inserts, dividers (e.g., for sets), stabilizing frames or die-cut mailers.
Learn more about shipping-ready structures we manufacture: Packaging.
3) Select the right board and structure instead of “overpacking”
Corrugated board isn’t “one board”. The number of plies and flute depends on product weight, fragility, transport conditions and stacking.
If you need support selecting 2/3/5/7-ply board for shipping, see: Corrugated board.
4) Test, don’t guess: ECT/BCT and quality control
Reducing material without testing can be a false saving. Strength tests help keep shipments safe and complaint rates low.
See what our testing facilities and approach look like: Research and Technology (R&D).
5) Standardize pack-out (SOP) so no one “adds fill by feel”
Void fill is often a symptom of missing process. Create simple SOPs for TOP SKUs: photo + 3 steps + a void fill limit. Add a random quality check every X parcels – results stabilize quickly.
6) Simplify for recycling: mono-material and easy separation
If your outer pack is corrugated, keep the whole pack as “paper-based” as possible: corrugated + paper add-ons. The fewer mixed materials and hard-to-separate elements, the better for recycling and for the customer.
Learn more about our environmental approach: Sustainable development.
7) Design for returns and second life
Returns are standard in e-commerce. Packaging that supports a simple return (without adding extra materials) reduces waste across the whole cycle.
If functionality matters as much as unboxing and brand consistency, see what’s possible in our Packaging offer.
Recycling and “design for recycling”: what makes the biggest difference?
“Recyclable” should mean: easy to sort and process. The core rules are simple: fewer materials, simple construction, no elements that are hard to separate, and clear guidance for the customer.
Sustainable packaging and regulations: why this matters right now
EU packaging and packaging-waste rules reinforce the trend of waste minimization and designing for recycling. In practice, for e-commerce this usually means more pressure to reduce “air” in parcels, redundant materials and add-ons that are hard to sort.
To understand our approach to sustainability and compliance, see: Sustainable development and Certifications and Awards.
Practical examples: 3 e-commerce scenarios
1) Cosmetics / small items
Problem: small products shipped in a medium box → lots of void fill. Solution: die-cut box + insert that holds the product. Result: faster pack-out and less “topping up”.
2) Fragile products (e.g., glass)
Problem: loose fill compacts and the product hits the box walls. Solution: dividers + rigid structure + strength testing. Result: better stabilization and repeatability.
3) Apparel / non-sensitive products
Problem: a “one box for everything” approach → empty space inside. Solution: right-sizing + removing void fill. Result: less material and lower shipping volume.
Mini checklist to implement in 30 days
- Week 1: TOP SKUs and baskets, photos of current pack-out, baseline data on damages/returns.
- Week 2: 2–3 prototypes (smaller box + insert), draft SOP.
- Week 3: pilot at a selected volume, measure packing time and material usage.
- Week 4: scale and fine-tune the final formats.
If you’d like us to prepare material and process recommendations, go to: Packaging audit or see the offer: Shipping-ready packaging.
