Reducing Transportation Costs Through Packaging Volume Optimization

Understand volume impact

Packaging volume optimization starts with recognizing how unused space inflates your freight bills. Every cubic inch you ship costs money, whether you’re sending glass vials or bulk electronics. By cutting wasted voids you’ll lower dimensional weight charges, improve cube efficiency, and move more product per pallet.

Why volume matters

• Carriers price shipments on dimensional weight when density falls below a set threshold
• Less-empty space means you avoid costly “dim weight” billing
• Better-packed pallets fit more units in the same trailer footprint

Cost drivers in transit

• Dimensional weight fees on air and LTL shipments
• Fewer units per load triggering more trucks or flights
• Extra handling when irregular spaces require blocking and bracing

Assess current packaging

Before you redesign, audit your cartons and pallets to spot wasted room. A quick scan of your top 10 SKUs can reveal major opportunities.

Audit package dimensions

1. Measure inner carton length, width, height
2. Record actual product dimensions including protective inserts
3. Calculate void percentage per carton

Identify wasted space

• Highlight SKUs with more than 20% empty volume
• Note multi-product cartons where uniform cells could help
• Flag unstable pallets needing extra dunnage

Optimize partition design

Fiber partitions let you structure cartons into uniform cells, eliminating contact damage and wasted voids. You’ll protect high-value items and shrink your overall package dimensions.

Use fiber partitions

• Create rigid cell walls that resist side loads and vibration (Premier Packaging)
• Eliminate bottle-to-bottle impact for glass, plastic, or jars

Customize cell geometry

• Choose cell size to match each product’s footprint
• Adjust caliper and fluting for your weight requirements
• Trial samples on your packing line to validate speed and fit

Reinforce with honeycomb

At the pallet or container level, honeycomb brings exceptional compression strength in a lightweight format. You’ll secure loads and shave inches off your total height.

Benefits of honeycomb

• High compression resistance for stacked pallets
• Even force distribution to prevent point loading
• Lightweight, recyclable, and cost effective (Premier Packaging)

Pallet-level protection

• Layer honeycomb sheets between pallets for vertical support
• Use edge protectors to maintain carton alignment
• Pair with honeycomb paperboard for a full eco-friendly system

Calculate savings & ROI

Quantify the impact of your volume cuts so you can justify investments in partitions and honeycomb.

Volume reduction metrics

• Void reduction percentage after redesign
• Units per pallet before vs after optimization
• Trailer or container density increase

Shipping cost comparison

Implement sustainable practices

Optimizing volume goes hand in hand with greener packaging. As you minimize materials and avoid overpacking, you’ll also strengthen your brand’s eco-credentials.

Recyclability factors

• Both fiber partitions and honeycomb paperboard are curbside recyclable
• Reduced material use lowers your carbon footprint
• Leaner pallets mean fewer trucks on the road

Collaborate with engineers

• Work with your packaging engineers to tailor solutions for each product line
• Run line-trial samples to confirm fit, speed, and protection
• Collect regular feedback from warehouse teams on handling and recycling

Next steps

1. Audit your top SKUs for void space
2. Pilot fiber partitions in a sample carton run
3. Layer honeycomb reinforcement at pallet level
4. Track volume, cost, and sustainability metrics
5. Scale successful designs across your network

By focusing on packaging volume optimization you’ll slash transportation costs, boost load securement, and support your sustainability goals all at once. Start small, measure fast, and watch your supply chain become leaner, greener, and more cost effective.