Your 2026 Mid-Year Packaging Consumables Audit

Aug 13, 2026 · 3 min read

COST SAVINGS & OPERATIONS

We’re halfway through the year — which means it’s the perfect time to take a hard look at one of the most overlooked line items in your operational budget: packaging consumables. Tape, stretch film, shrink film, protective packaging, mailers — purchased in high volumes, used every day, and rarely scrutinized. That’s exactly why they’re such a reliable source of hidden waste.

A mid-year audit of your consumables usage doesn’t just trim costs. It sharpens your entire packaging operation heading into the back half of the year. Here’s how to do it right.

THE PROBLEM

Why Consumables Spending has Quietly Escalated

Most operations review purchasing at year-end, after the budget is already spent. Consumables waste accumulates across three predictable failure modes: using the wrong product for the application, ordering more than you actually use, and running manual processes where automation would pay for itself quickly. None of these show up as a single line item — they hide in aggregate spend, re-work labor, and damage claims.

STEP-BY-STEP

The 7-Step Mid-Year Audit

01	Pull spend by consumables category Break out carton sealing tape, stretch and shrink film, protective packaging, specialty tapes, and mailers separately. Capture units purchased, total spend, and cost per unit for each. This baseline is what everything else measures against.

02	Compare what you ordered vs. what you used Overstock can create inventory carrying costs and, depending on storage conditions and product type, may affect long-term performance.

03	Audit product-to-application fit The wrong product costs more than the right one, even at a lower unit price. Over-specified tape on lightweight boxes wastes money. Under-specified tape on heavy cartons creates failures, re-packing labor, and damage claims. Match specification to application.

Evaluate water-activated tape as a carton sealing alternative

Water-activated tape (WAT) bonds directly to the corrugated surface, creating a permanent, tamper-evident seal. For high-value shipments and e-commerce returns, WAT often delivers better total cost of ownership — fewer failed seals, less tape per carton, fewer damage claims.

Review protective packaging for right-sizing

Bubble wrap, foam, air pillows, and void fill are the highest-waste category in most operations. Sample outbound packages — are products moving inside the box? Is there excessive dunnage adding weight and dimensional charges without adding protection?

06	Stretch & shrink films Stretch and standard polyethylene films are engineered for consistent load containment. High-performance stretch options reduce consumption per pallet and lower film cost at scale.

07	Consolidate your supplier relationships Sourcing consumables from multiple vendors fragments purchasing power and complicates inventory management. A single-source supplier with broad portfolio coverage typically unlocks volume pricing, simplified reordering, and faster issue resolution.

IPG SOLUTIONS

Purpose-Built Products for Every Audit Finding

IPG’s portfolio spans the full scope of packaging consumables — meaning audit findings across every category map directly to a solution.

Carton Sealing Tape & Water-Activated Tape

A full range of pressure-sensitive and WAT options matched to box weight, transit requirements, and tamper-evidence needs — from standard carton sealing to high-performance reinforced solutions.

Stretch & Shrink Films

High performance stretch film and standard polyethylene films engineered for consistent load containment. High-performance stretch options reduce consumption per pallet and lower film cost at scale.

Protective Packaging

Bubble, foam, air cushion, and void fill products — including on-demand bubble systems that right-size protection and reduce stored inventory volume.

Case Sealing Equipment

IPG’s case sealers work as a closed-loop system with IPG consumables. On high-volume lines, automation typically pays for itself within 12–18 months in labor savings alone.

CHOOSING THE RIGHT SOLUTION

Matching Audit Findings to Product Decisions

AUDIT FINDING	RECOMMENDED ACTION	KEY BENEFIT
Over-specified tape on lightweight cartons	Switch to standard carton sealing tape matched to box weight	Immediate unit cost reduction, no integrity trade-off
Failed seals or damage claims on heavy cartons	Upgrade to water-activated tape (WAT)	Peermanent bond, tamper-evident, fewer re-packs
High stretch film cost per pallet	Trial high performance stretch film on highest-volume lines	More wraps per roll, reduced film consumption
Excessive void fill or dunnage	Right-size protective packaging; evaluate on-demand solutions	Lower material cost, reduced DIM weight charges
High labor cost on tape application	Evaluate IPG case sealing equipment	Labor Savings
Multi-vendor fragmentation	Consolidate under IPG as single-source supplier	Volume pricing, simplified reordering, accountability

BOTTOM LINE

Packaging is the Variable you can Control

You can’t control carrier handling conditions, ambient temperatures, or unexpected transit delays. What you can control is how well your packaging performs under those conditions — and how efficiently your operation consumes materials in the first place.

A mid-year audit typically uncovers savings in three areas simultaneously: product-application mismatches, over-ordering patterns, and process inefficiencies that better-fit products or equipment can solve. The operations that do this review at mid-year don’t just save money — they go into Q3 and Q4 better positioned and better stocked.

Feady to optimize your packaging consumables?

Explore IPG’s full product portfolio or connect with an expert for a packaging audit.

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Your 2026 Mid-Year Packaging Consumables Audit

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