5 Common Packaging Mistakes Costing You Money (And How to Fix Them)

Poor packaging puts products at risk. And in doing so, it also puts your profits at risk. High shipping costs, expensive returns, lost sales and compliance fines are just some of the many business costs that can add up as a result of common packaging errors.

At Fencor Packaging Group, our proven 96–98.5% On-Time, In-Full (OTIF) delivery record shows we understand that reliability is paramount. This article highlights the hidden costs of these mistakes and shows how a design-led, strategic approach transforms packaging from a liability into a competitive advantage.

1. Right-Size Your Packaging to Cut Shipping Costs & Waste

The “one-size-fits-most” stock box can often prove to be a false economy. While the per-unit price may seem low, it can create a cascade of inefficiencies throughout your operation.

The Cost: Oversized boxes require excessive void fill, increasing material expenditure. More significantly, they can incur dimensional (DIM) weight penalties from shipping carriers, leading to unnecessary charges for shipping empty space. This approach also increases manual packing time and is often unsuitable for efficient, automated packing lines.

The Solution: A bespoke approach engineers packaging to your product’s exact dimensions and optimised to minimise the manufacturing process. Our process of expert packaging design eliminates costly void fill and reduces shipping weight. For example, redesigning Shelf-Ready Packaging for a premium chocolate brand to an all-in-one solution removed the need for adhesive tape and material wastage, maximising their on-shelf impact. In addition, optimising the design of the origination (print plates and cutting tools) reduced the manufacturing process by 30%! 

2. How Low-Quality Boxes Increase Product Damage & Returns

Product damage can erode profit and customer trust. The root cause is often not just a poor design, but the poor quality and inconsistency of its manufacture.

The Problem: Some suppliers may use older machinery that damages the corrugated structure, damaging its integrity. To compensate for this weakness, they are often forced to use a heavier, and more expensive grade of material – a cost that is passed directly on to you.

The Cost: This can lead to a higher rate of product damage in transit. A single return generates a domino effect of costs: product replacement, reverse logistics, reshipping, and customer service labour. As UK consumer studies show, the negative experience has a lasting impact, with 78% of shoppers unlikely to repurchase from a brand following a poor delivery.

The Solution: We invest in modern, high-end BOBST machinery that maintains the matrial structural integrity. This allows us to use lighter, optimised, and more cost-effective materials that provide superior protection without over-engineering. It’s a commitment to excellence backed by our Quality Promise and rigorous pre-shipment testing.

3. Improve Brand Perception with Custom Packaging Design

In e-commerce, the shipping box is often the first physical interaction a customer has with your brand. A plain, generic box is a missed opportunity.

The Problem: Major brands are highly sensitive about brand identity and colour management. Achieving true brand consistency on a printed box is a technical challenge that requires more than just a logo.

The Cost: A generic box delivers a forgettable, transactional experience with zero marketing return. It fails to build the emotional connection that drives loyalty and user-generated content on social media, a critical failure when 72% of consumers agree packaging design influences their purchasing decisions.

The Solution: We meet these stringent branding requirements by merging robust structural engineering with high-impact graphic design. Our investment and commitment to colour management ensures colour accuracy. We transform your packaging into a powerful and consistent brand asset, creating memorable bespoke e-commerce box solutions.

4. Avoid Supply Chain Failure with a Reliable Packaging Partner

The single most significant packaging mistake is choosing an unreliable supplier.

The Problem: The biggest cost isn’t a damaged box, it’s no box at all. When your packaging doesn’t arrive, you cannot dispatch your products. Your entire operation risks grinding to a halt.

The Cost: This leads directly to lost sales, production stoppages, and frustrated customers. Businesses can be forced to tie up working capital in excessive safety stock and waste valuable warehouse space storing empty boxes instead of revenue-generating products.

The Solution: We deliver proven operational reliability, backed by a world-class standard delivery record. Our Stock and Serve facility offers a direct solution for expert packaging inventory management, enabling Just-in-Time delivery that frees up your capital and your space.

5. Sustainable Packaging: Meeting Regulations & Customer Expectations

As sustainability becomes a greater focus for both regulators and consumers, adopting sustainable packaging is an increasingly important business decision.

The Cost: Businesses should consider two main factors. First, there are the financial implications of non-compliance with UK regulations, such as the Extended Producer Responsibility (EPR) framework. Second, there is the opportunity to build brand loyalty with a growing number of environmentally conscious consumers.

The Solution: Our commitment to sustainability is verifiable, not just a claim. Through our part-ownership of CorrBoard UK, the UK’s only carbon-neutral manufacturing corrugated sheet plant, we provide a genuinely sustainable component for your supply chain. We recently worked with an online horticultural retailer to replace plastic plug plant trays with recyclable cardboard trays that have been designed for water resistance during the transit period of the plants. This enables the retailer to safely ship moist plug plants while ditching single-use plastics. Partner with us to enhance your brand’s ESG scorecard with our sustainable packaging.

Conclusion: Choose a Partner, Not a Supplier

The key takeaway from these errors is that they all stem from working with tactical, cost-focused suppliers. 

A strategic partnership with Fencor Packaging Group is an investment in performance, transforming your packaging from a simple cost centre into a source of profound competitive advantage.

To discuss how we can help, book a complimentary packaging audit. We’ll analyse your supply chain and demonstrate where savings and efficiencies can be made. 

You can reach our team on 01733 233884.