How Athens Helps You Spot Overpackaging (and Recover Margin)
Purchasing managers, operations managers, and plant managers all have budget pressure right now. Many companies have never truly evaluated whether they are using more packaging than necessary.
This guide is designed to help you identify fast, measurable improvements without sacrificing protection or customer experience.
Why This Sneaks Up on Teams
Many companies focus on the price of packaging materials, but often overlook how packaging design and application impact total cost.
A box that is slightly oversized, stretch film that is heavier than necessary, or excessive void fill may seem insignificant on a per-unit basis.
Across thousands of shipments, these small inefficiencies can add up to tens of thousands of dollars annually.
At Athens, we routinely help customers uncover hidden packaging costs without sacrificing product protection or customer experience.
The 5 Signs to Watch
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You're Shipping Air
Oversized cartons increase corrugated costs, void fill usage, freight expenses, and warehouse space requirements.
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Your Stretch Film Hasn't Been Evaluated in Years
Many operations continue using the same film specification after loads, equipment, and shipping conditions have changed.
A properly engineered downgauging program can often reduce film consumption while maintaining load integrity.
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You're Using More Tape Than Necessary
Multiple strips of tape or excessive tape application can increase material costs and labor time.
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Product Damage Isn't Improving
Adding more packaging does not always mean better protection.
In many cases, the right packaging performs better than simply adding more material.
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Packaging Decisions Are Based on Habit
"We've always done it this way" is often one of the biggest drivers of unnecessary packaging spend.
Where Teams Usually Find Savings First
- Corrugated right-sizing
- Stretch film downgauging
- Shrink film optimization
- Tape reduction programs
- Protective packaging redesign
- Packaging automation opportunities
- Freight and cube utilization improvements
Tape Options to Pair with This Strategy
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Free Packaging Optimization Assessment
Athens' packaging specialists can evaluate your current packaging process and identify opportunities to reduce material usage, improve efficiency, and lower overall packaging costs.
Our assessment reviews:
- Corrugated usage
- Stretch film consumption
- Tape application
- Shrink packaging
- Labor efficiencies
- Equipment opportunities
Schedule your complimentary Packaging Optimization Assessment today and get a clear view of where cost, efficiency, and protection can be balanced better.