The cheapest box isn’t always the cheapest way to pack a product.
We see this particularly when businesses are using standard boxes for products that aren’t a particularly good fit. The box itself might be inexpensive, but then you need extra void fill, more protective packaging or additional time at the packing bench to make it work.
For fragile products, there’s another cost to consider too: what happens if the packaging doesn’t do its job.
That’s why, when we look at whether bespoke packaging is worthwhile, the price of the box is only part of the conversation.
Designing the packaging around the product
The bottle packaging pictured below is a good example of this.
The box uses corrugated dividers to create individual compartments for the bottles, keeping them separated and supported within the outer box.
Bottles are an obvious example of a product where protection matters. A breakage doesn't just mean replacing the damaged item. There can also be the cost of another delivery, replacement packaging and the time spent sorting the problem out.
There are plenty of ways to protect fragile products using standard packaging, and we've covered some of them in our guide to internal packaging for fragile items.
But if you're regularly sending the same product, it can be worth looking at whether packaging designed around it would make the whole process simpler.
It's not just about preventing damage
A box that is too large for its contents usually needs something to fill the empty space.
Sometimes that's unavoidable. But if you're adding large amounts of void fill to the same type of order every day, it's worth looking at the box as well as the filler.
A closer-fitting box may use less material and can make packing more straightforward. Depending on what and how you're shipping, it may also reduce the size of the finished parcel.
Packing time is another part of the equation. An awkward product that needs wrapping, positioning, filling and securing takes longer to prepare than one with packaging that has been designed to hold it properly.
Individually, these can look like small costs. At volume, they're worth paying attention to.
Sometimes bespoke can simplify what you already use
One of our recent projects took a slightly different approach.
We produced one core box that could be used with three interchangeable custom sleeves.
Rather than producing a completely separate packaging format for each variation, the main box remained the same and the sleeve could be changed.
It's a useful example of what bespoke packaging can actually involve. It doesn't always mean adding more packaging formats to your stockroom. A good design can sometimes help simplify them.
This is particularly relevant for businesses with several related products, ranges or variations that need different presentation but don't necessarily need completely different boxes.
You can see more examples of the different types of bespoke packaging TEC can produce here.
Where should you look for savings?
If you're reviewing packaging costs, we'd look beyond the amount you're paying for each box.
How much additional protective material goes into each order? How long does it take to pack? Are products being damaged? Are you holding several box sizes because none of them is quite right for the job?
You might find that your existing standard packaging is already doing exactly what you need it to do.
But if you're repeatedly adapting a box to suit the product inside it, particularly at higher volumes, that's when it's worth looking at the alternatives.
We've previously looked at some of these wider costs in our guide to keeping packaging costs down when selling online.
Standard or bespoke? Start with what you're packing
There isn't a point where every business suddenly needs to switch to bespoke packaging. It depends on the product, the quantities involved and what your current packing process looks like.
For TEC, the starting point is the product and what the packaging needs to achieve.
Sometimes the answer will be a standard box from our existing range. Sometimes a different box size or protective material is enough. And sometimes there's a good commercial case for creating something specifically for the job.
If you're using more packaging than you'd like, dealing with breakages or spending too much time making standard packaging fit your products, talk to TEC Packaging about bespoke packaging. We can look at what you're currently using and whether there's a better way to pack it.