How to Reduce Packaging Waste in Ecommerce Fulfilment

The Growing Problem of Packaging Waste: A Guide for UK Ecommerce Brands.

Ecommerce has transformed the way people shop, but it has also contributed to a growing packaging waste crisis. In the UK alone, businesses generate an estimated 12 million tonnes of packaging waste annually—much of it from ecommerce shipments. Customers are becoming increasingly aware of this issue, with 74% of UK shoppers preferring to buy from brands with sustainable packaging.

For ecommerce businesses, reducing packaging waste isn’t just good for the planet—it can also lower costs, improve brand reputation, and enhance customer satisfaction.

This guide explores practical ways to minimise packaging waste in ecommerce fulfilment while maintaining product protection and efficiency.

Step 1: Conduct a Packaging Audit

Before making changes, assess how much packaging your business currently uses.

Key Questions to Ask:

✅ Are we using more material than necessary?
✅ Are our packaging sizes optimised for our products?
✅ How much of our packaging is recyclable or compostable?
✅ What are our most common packaging-related complaints from customers?

A simple audit can reveal inefficiencies, such as excessive void fill, oversized boxes, or materials that aren’t eco-friendly.

Step 2: Right-Size Your Packaging

One of the biggest contributors to packaging waste is using boxes that are too large for the product. Oversized packaging not only wastes material but also increases shipping costs and carbon emissions.

How to Right-Size Packaging:

• Use custom-sized boxes that fit products snugly, reducing the need for extra fillers.
• Implement multi-size packaging automation that adjusts box sizes dynamically.
• Consider padded mailers or envelopes instead of boxes for smaller, non-fragile items.

Example:
A UK fashion brand reduced packaging waste by 30% by switching from large, generic boxes to custom-fit mailers that better suited their clothing products.

Step 3: Switch to Sustainable Packaging Materials

Not all packaging waste is avoidable, but switching to sustainable materials can significantly reduce environmental impact.

Eco-Friendly Packaging Options:

🌱 Recycled Cardboard Boxes – Made from post-consumer waste, reducing the demand for virgin materials.
🌱 Compostable Mailers – Break down naturally without harming the environment.
🌱 Water-Activated Paper Tape – A sustainable alternative to plastic packing tape.
🌱 Cornstarch Packing Peanuts – Biodegradable and dissolve in water, unlike polystyrene.

Did You Know?
Amazon UK has committed to eliminating single-use plastic packaging in fulfilment centres, favouring paper-based materials instead.

Step 4: Reduce or Eliminate Void Fillers

Void fillers (like bubble wrap and air pillows) are often overused. While they protect fragile items, they also contribute to unnecessary waste.

Alternatives to Bubble Wrap & Plastic Fillers:

♻ Recycled Paper Cushioning – Provides padding while being recyclable.
♻ Shredded Cardboard or Paper – Repurpose old materials into protective fillers.
♻ Moulded Pulp Inserts – Secure fragile items without using plastic.

Example:
A UK electronics retailer switched from plastic air pillows to moulded pulp inserts, reducing their plastic waste by 45% per year.

Step 5: Offer Minimal Packaging Options at Checkout

Some customers prefer less packaging. Giving them the option at checkout can help reduce waste while providing a personalised shopping experience.

Ideas for Reducing Packaging at Checkout:

✅ Offer a “Minimal Packaging” option for eco-conscious shoppers.
✅ Give customers the choice of reusable packaging for an extra fee.
✅ Allow bulk shoppers to consolidate items into fewer shipments.

Example:
An online beauty brand introduced a “less packaging” option at checkout and saw 22% of customers opt for minimal packaging in their orders.

Step 6: Implement a Packaging Take-Back Programme

Encouraging customers to return used packaging can be a game-changer in reducing waste.

How a Take-Back Programme Works:

• Customers return boxes, mailers, or protective fillers for reuse or recycling.
• Offer incentives like store credit or discounts for participating.
• Partner with recycling firms or sustainable logistics providers.

Example:
A UK jewellery brand introduced a packaging return scheme where customers could send back boxes for a £5 store credit. Over 60% of customers reused the packaging, saving thousands of boxes from landfill.

Step 7: Train Your Fulfilment Team on Sustainable Practices

Switching to sustainable packaging is just the first step. Ensuring staff are trained in waste reduction techniques will help maintain eco-friendly fulfilment practices.

Best Practices for Warehouse Teams:

✅ Pack efficiently, using only necessary materials.
✅ Reuse returned packaging where possible.
✅ Educate team members on sorting and recycling packaging waste.

Example:
A UK-based homeware ecommerce brand reduced packing time by 20% after training their fulfilment staff on efficient packaging techniques.

Step 8: Work with a Green Fulfilment Partner

If you outsource fulfilment, choosing a sustainable 3PL (third-party logistics provider) can help ensure your packaging strategy aligns with your environmental goals.

Questions to Ask a Potential Fulfilment Partner:

✅ Do you use recyclable or biodegradable packaging materials?
✅ How do you minimise waste in your fulfilment centres?
✅ Do you offer carbon-neutral or low-emission delivery options?

At E-PickPack, we specialise in eco-friendly fulfilment solutions for UK ecommerce brands, helping businesses reduce waste without sacrificing efficiency.

Conclusion: Sustainable Packaging is a Win-Win

Reducing packaging waste isn’t just about being eco-friendly—it’s about making your business more efficient, cost-effective, and customer-centric. By right-sizing packaging, using sustainable materials, and offering waste-reduction initiatives, you can significantly cut down on unnecessary waste while strengthening your brand’s reputation.

At E-PickPack, we help ecommerce businesses transition to sustainable fulfilment practices that reduce waste, lower costs, and keep customers happy.

Ready to make your packaging more sustainable?

Get in touch today and let’s build an eco-friendly fulfilment strategy for your business.

FAQs

Q: What is the best sustainable packaging for fragile items?
Recycled paper cushioning, moulded pulp inserts, and shredded cardboard are excellent alternatives to plastic fillers.

Q: How can reducing packaging waste save my business money?
Smaller, right-sized packaging reduces material costs, shipping expenses, and storage space requirements.

Q: Are biodegradable mailers better than recyclable boxes?
It depends on your business. Biodegradable mailers are great for lightweight, non-fragile items, while recyclable boxes offer better protection for heavier goods.

Q: How do I encourage customers to choose minimal packaging?
Offer incentives such as discounts, loyalty points, or a simple “minimal packaging” option at checkout.

Q: Can a fulfilment partner help with sustainable packaging?
Yes! Many 3PLs, like E-PickPack, offer eco-friendly packaging and waste-reduction strategies for ecommerce brands.