Cutting packaging spend isn’t about using less—it’s about auditing smarter across materials, labor, and performance. By identifying hidden inefficiencies and optimizing how packaging systems work together, companies can reduce costs without sacrificing speed, safety, or reliability.
1. The "Hidden Waste" Assessment
Before you can save, you must measure. Most companies overspend because they use "Legacy Specs"—packaging standards set years ago that no longer fit current shipping needs.
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Compare your current box sizes to your actual product dimensions. If you have more than 2 inches of void space, you are paying for excess material and increased dimensional (DIM) weight.
2. Evaluate the "Cost-Per-Seal" (Not Cost-Per-Roll)
A common mistake in audits is focusing on the invoice price of a roll of tape.
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Calculate how much tape is actually used per box. If a cheap tape requires three strips to stay closed, it is more expensive than a premium tape (like IPG’s Water-Activated Tape) that only requires one.
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Total Sealing Cost = (Cost per Inch x Inches Used) + Labor Time
3. Analyze Damage Rates vs. Material Strength
If your audit shows high material savings but rising "Damaged in Transit" reports, your audit is failing.
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Review your "Damages and Returns" log. True cost savings come from finding the "Sweet Spot" where material weight is minimized without compromising the integrity of the seal.
4. Labor and Throughput Audit
Packaging costs aren't just materials; they are minutes.
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Time your packing line. If workers are struggling with manual dispensers or re-taping boxes that pop open, your labor costs are eroding your material savings.
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Consider semi-automated case sealers that standardize tape usage and speed up the process.
5. Leverage Packaging Diagnostics
The final step of a professional audit is using data-driven tools. IPG’s Packaging Diagnostics service automates this audit process by looking at the interaction between your machinery, your materials, and your labor.
Stop guessing if you're overspending. Our team can perform a comprehensive cost-savings audit to identify exactly where your materials—and your budget—are being wasted.
Visit itape.com to start your audit today.
