Modern ecommerce has a visible inefficiency: small items frequently arrive in oversized boxes packed with void fill. This isn’t just inconvenient — it signals a lack of care, increases waste, and inflates cost. In many cases, the product could fit in a hand, yet arrives in a parcel sized for a small appliance.

The core issue is air. When a significant portion of a box is empty, the supply chain is effectively transporting packaging volume rather than value.

Right-sized packaging is increasingly a strategic lever because it directly affects:

• Cost and margin: less cardboard, less void fill, and better space utilisation reduce material and transport cost.

• Operational throughput: automation can increase output without increasing headcount.

• Regulatory and CSR readiness: requirements differ by market, but the direction is consistent — packaging reduction and sustainability expectations are increasing.

• Customer experience: right-sized packaging improves perceived quality, reduces frustration, and strengthens brand association through a better unboxing experience.

The takeaway is simple: packaging is no longer “just a box”. It is part of the customer journey, and a driver of fulfilment economics.

Packaging waste continues to grow as parcel volumes rise. Even when materials are recyclable, the most sustainable outcome is avoiding waste in the first place. Ecommerce is a major contributor to packaging volume, which makes optimisation one of the most practical sustainability interventions available to operators today.

Traditional packing remains common, but manual processes rarely optimise box selection consistently. Decisions vary by operator, box availability, and time pressure — typically resulting in oversized packaging and excessive void fill.

A second step is height reduction, which improves outcomes but still leaves empty volume in length and width.

The most complete approach is box-last: packaging created after the order is measured, producing a tailored box for each shipment. This enables systematic reduction of empty space, while also reducing touchpoints and standardising output quality.

Automated right-sized packaging enables several operational benefits:

• High throughput at scale: dynamic packaging output that adapts to single-SKU and multi-line orders.

• Reduced material usage: less cardboard and minimal or no void fill.

• Improved load efficiency: better carton density means better truck utilisation and fewer wasted cubic metres.

• Process standardisation: packaging quality becomes consistent across shifts and peak periods.

• Improved tamper resistance: automated sealing methods can reduce reliance on tape, improving integrity in challenging conditions.

For high-growth ecommerce markets, these gains compound quickly across volume.

In fast-growing regions, the cost of inefficient packaging rises every year. As order volumes increase, “small” inefficiencies become structural: warehouse space pressure, higher transport spend, higher labour load, and escalating waste. Right-sized packaging is positioned as a practical response — delivering cost savings, sustainability improvements, and a better customer experience without relying on perfect operator behaviour.

Right-sized packaging is one of the most direct ways to improve fulfilment economics and customer experience simultaneously. By reducing “air shipping” and standardising output through automation, retailers and ecommerce operators can lower cost-to-serve, reduce packaging waste, improve truck utilisation, and meet rising expectations for sustainable, professional delivery.