Streamlining packaging formats: reducing empty space and boosting performance

An improperly sized package automatically creates empty space. Yet shipping costs are increasingly based on volumetric weight. Shipping air therefore amounts to paying for wasted space. In certain e-commerce or B2B environments, the average fill rate ranges between 42% and 46%. More than half of the shipped volume contains no product.

• An invisible but massive cost

This finding often comes as a surprise when objectively assessed. Many companies believe they have optimized their packaging, until a volumetric analysis reveals that air is the primary “commodity” being transported. This empty space is not neutral. It results in more pallets, more trucks, more handling, more emissions, and ties up capital in consumables.

Streamlining packaging formats radically changes this equation. By combining standardized packaging with automatic adjustment of package height, it becomes possible to increase the average fill rate and reduce the total volume shipped by up to 30%.

This figure is no small matter. A 30% reduction in volume means up to 30% fewer pallets to handle and wrap. It means up to 30% fewer trailers. It means fewer trucks on the roads and an immediate reduction in CO2 emissions. It also means up to 50 to 60% fewer packing materials, or even none at all when the package fits perfectly.

High seasonality highlights structural weaknesses. Too many different formats complicate cardboard procurement. Non-standardized packaging slows down automated lines. Operators spend time searching for the right package, forming it manually, and correcting errors.

• Multiple formats that slow down logistics

During slow periods, these imbalances are absorbed. During peak periods, they become critical. Every second counts. Every error causes a ripple effect. A simple shortage of one cardboard format can disrupt an entire line. Teams compensate, but at the cost of increased fatigue and a decline in quality.

• When seasonality amplifies the flaws

Standardizing shipping formats, sizing boxes for automated lines, and automating forming, height reduction, cap placement, and labeling—all of these steps help stabilize productivity.

This stability is essential. It means that performance no longer depends solely on human effort but on a robust process. Cycle times become predictable. Production rates remain consistent even as volumes increase. Teams gain peace of mind because the system absorbs some of the pressure.

Reducing material usage does not mean weakening the package. On the contrary, better-designed packaging distributes mechanical stresses more effectively. Stacking strength improves, transport stability is enhanced, and the risk of crushing decreases.

Optimizing the fill rate also helps reduce cushioning materials by 50 to 60% when they are retained. This enhances service quality. A well-fitted, sturdy, and proportionate package improves the customer experience. Conversely, an oversized package conveys an image of waste, while a fragile package leads to breakage and returns.

In a context where the customer experience doesn’t end with delivery but includes the moment of opening, packaging becomes a factor in brand perception. Less empty space, less waste, a sense of consistency: these details contribute to customer loyalty.