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9 Ways to Cut Packaging Costs Without Cutting Quality

The fastest packaging savings come from buying used and reconditioned boxes, right-sizing cartons to reduce void fill, standardizing dimensions, backhauling freight and selling your surplus. Together these routinely cut packaging spend 20–50%.

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The fastest packaging savings come from buying used and reconditioned boxes, right-sizing cartons to reduce void fill, standardizing dimensions, backhauling freight and selling your surplus. Together these routinely cut packaging spend 20–50%.

Start with the biggest lever: buy used

Switching non-critical loads from new to Grade A used Gaylords and cartons is the single largest line-item saving for most operations — often 40–70% on the box itself.

Right-size to kill void fill

Every inch of empty space is dunnage you pay for and dimensional weight you ship. Matching carton size to product trims both material and freight.

Standardize and backhaul

Standard dimensions unlock volume pricing and recurring supply. Backhauling boxes on freight you already run cuts empty miles and cost.

Finally, sell your surplus — a disposal cost becomes revenue and a diversion metric at the same time.

7 min read · Updated April 2026

How to Reduce Packaging Costs — 9 Practical Tactics · USA Boxes Recycle