How to Lower Freight Costs with Innovative Packaging Solutions

Freight costs can be a significant part of a business’s operating expenses, especially for companies that rely on shipping large volumes of goods. By optimizing how products are packed and shipped, businesses can realize substantial savings. Below are some key strategies to lower freight costs through smarter packaging.

1. Optimize Package Size and Weight

The size and weight of your packaging directly affect freight charges. Shipping companies typically charge based on dimensional weight (the amount of space a package takes up) or the actual weight of the package, whichever is greater. Using packaging that minimizes unused space can significantly reduce these charges. Solutions include:

• Custom-sized packaging: Tailor the packaging to fit the product perfectly, reducing empty space.
• Lightweight materials: Switch to lighter yet durable materials such as molded pulp or honeycomb cardboard to decrease the overall weight without sacrificing protection.

2. Invest in Multi-Use and Returnable Packaging

For businesses that regularly ship and receive products, using multi-use or returnable packaging can lead to long-term savings. Although the upfront costs might be higher, the reuse potential can offset those initial expenses over time. Solutions include:

• Collapsible crates: These can be flattened after delivery, saving space on return shipments and minimizing freight costs.
• Durable totes and containers: These can be used multiple times and are ideal for businesses that ship in closed-loop supply chains, where products are frequently sent back and forth between destinations.

3. Use Smart Packaging Designs to Maximize Space Utilization

Space is a premium commodity in freight transport. The more efficiently products can be packed into shipping containers or onto pallets, the lower your costs. Smart packaging designs aim to maximize the use of available space, reducing the number of shipments required. Solutions include:

• Stackable designs: Packaging that is designed to stack efficiently allows for better utilization of vertical space.
• Modular packaging: Modular systems enable various components of the shipment to fit together seamlessly, optimizing the available space in trucks and containers.

4. Implement Sustainable Packaging Solutions

Sustainability isn’t just good for the environment; sustainable packaging solutions often emphasize lightweight materials, recyclability, and compact designs, which can lead to reduced shipping weights and smaller package sizes. Solutions include: 

• Biodegradable materials: Many biodegradable materials, such as cornstarch-based plastics or recycled paper, are lighter than traditional materials.
• Right-sized packaging: By designing packaging that fits products more precisely, you not only reduce material usage but also cut down on wasted space, which translates into lower dimensional shipping costs.

5. Automate the Packaging Process

Human error and inefficiencies in manual packaging processes can contribute to higher freight costs. Automation can help streamline the packaging process, ensuring that products are packed more efficiently and consistently. Solutions include: 

• Automated packing machines: These systems can efficiently handle various tasks, such as filling, sealing, and labeling.
• Automated palletizers: These machines organize and stack goods onto pallets in the most space-efficient way, reducing shipping costs.

6. Partner with Arnold Packaging!

Our packaging experts can be a valuable ally in your efforts to lower freight costs through packaging. Arnold Packaging’s Engineers can give advice on where it’s best for your operations to optimize, consolidate or automate. 

Ready to save? Give us a call for a free consultation at 855-276-6537 or submit a quick form and we’ll get right back to you.

Laura Cadden
Arnold Packaging
Protecting Your Product & Your Profit