Procurement Glossary
Packaging reduction: strategies for sustainable optimization in Procurement
November 19, 2025
Packaging reduction refers to the systematic reduction of packaging materials while maintaining product safety and quality. This strategy is becoming increasingly important in Procurement , as it both reduces costs and supports sustainability goals. Find out below what packaging reduction involves, what methods are available and how you can successfully implement them in your procurement strategy.
Key Facts
- Reducing packaging can cut material costs by 15-30% and reduce CO2 emissions at the same time
- Legal requirements such as the Packaging Act and EU directives are driving implementation forward
- Optimized packaging reduces transport costs due to lower weight and volume
- Supplier cooperation is crucial for successful packaging reduction strategies
- Digital tools enable precise measurement and monitoring of packaging optimizations
Contents
Definition: Packaging reduction
Packaging reduction includes all measures to minimize packaging materials without compromising product integrity and functionality.
Key aspects of packaging reduction
The key elements include material optimization, design improvements and innovative packaging solutions. The focus is on the following approaches:
- Reduction in material thickness while maintaining stability
- Elimination of superfluous packaging layers
- Optimization of packaging sizes and shapes
- Use of lighter materials with the same protective function
Packaging reduction vs. packaging avoidance
While packaging reduction focuses on optimizing existing packaging, packaging avoidance aims to eliminate packaging altogether. Both approaches complement each other in a holistic sustainable packaging strategy.
Importance in strategic Procurement
Packaging reduction contributes to the decarbonization of the supply chain and supports compliance requirements. It enables cost savings and strengthens the company's sustainability positioning.
Methods and procedures
Successful packaging reduction requires systematic approaches and cooperation between various stakeholders along the value chain.
Analysis and valuation methods
The basis for this is a comprehensive inventory of all packaging components. Life cycle assessments evaluate the environmental impact of different packaging options.
- Packaging audit to identify optimization potential
- Material flow analysis along the supply chain
- Cost-benefit assessment of various reduction scenarios
Supplier integration and cooperation
The involvement of suppliers is essential for sustainable packaging solutions. Joint development projects and clear guidelines in the Supplier Code of Conduct create the necessary basis.
Technological implementation approaches
Modern technologies enable precise optimization through simulation and prototyping. Material substitution opens up new possibilities for lighter and more environmentally friendly packaging.
Tacto Intelligence
Combines deep procurement knowledge with the most powerful AI agents for strong Procurement.
Important KPIs for packaging reduction
Measurable key figures enable the systematic evaluation and management of packaging reduction measures along the entire value chain.
Quantitative reduction indicators
Basic metrics record the absolute and relative packaging reduction. These include weight and volume reductions as well as material savings per product unit.
- Packaging weight per product unit (kg/piece)
- Packaging volume reduction (%)
- Material cost savings (€/year)
- Packaging intensity (packaging/product weight)
Sustainability and environmental indicators
Environmental KPIs measure the environmental impact of packaging optimization. Scope 3 emissions from packaging are becoming increasingly relevant for climate accounting.
Efficiency and quality indicators
Operational key figures evaluate the impact on logistics and product quality. The recycling rate of the packaging materials used is becoming an important sustainability indicator.
Risks, dependencies and countermeasures
Packaging reduction involves specific risks that can be minimized through forward-looking planning and systematic risk management.
Product safety and quality risks
Excessive material reduction can lead to product damage, contamination or loss of quality. Comprehensive testing and step-by-step implementation are essential.
- Transport damage due to inadequate protection
- Product shelf life and freshness of food
- Compliance violations for regulated products
Supply chain dependencies
Dependence on specialized suppliers for innovative packaging solutions can lead to supply risks. Due diligence processes and supplier diversification reduce these risks.
Cost and investment risks
Initial investments in new packaging technologies and conversion costs can be considerable. A well-founded recycling rate analysis and long-term cost analysis are necessary for informed decisions.
.avif)
Practical example
An electronics manufacturer reduced the packaging volume of its smartphones by 35% by redesigning the packaging geometry and eliminating plastic inserts. The switch to recyclable cardboard packaging and optimized product arrangement led to annual cost savings of 2.3 million euros while simultaneously reducing CO2 emissions by 1,200 tons.
- Analysis of the existing packaging structure and identification of optimization potentials
- Development of alternative packaging concepts in cooperation with suppliers
- Pilot test with selected product lines and measurement of the effects
- Gradual roll-out to the entire product portfolio
Current developments and effects
The reduction in packaging is being driven by stricter regulations, technological innovations and changing consumer expectations.
Regulatory developments
New EU packaging regulations and national laws are tightening the requirements for packaging optimization. The Corporate Sustainability Reporting Directive increases transparency requirements.
- Extended producer responsibility for packaging
- Minimum recycling rates and reduction targets
- Stricter reporting obligations on packaging quantities
Technological innovations
AI-based optimization tools are revolutionizing packaging development through precise predictions and automated design optimization. Machine learning analyzes packaging performance and identifies potential for improvement in real time.
Circular economy and digitalization
The integration of recyclability assessments and digital tracking systems enables holistic optimization approaches. Product carbon footprint calculations are becoming standard.
Conclusion
Packaging reduction is becoming a strategic success factor in modern Procurement, combining cost savings with sustainability goals. Systematic implementation requires close supplier cooperation, in-depth analysis and continuous monitoring. Companies that take a proactive approach to packaging reduction position themselves advantageously for future regulatory requirements and market expectations.
FAQ
What is packaging reduction?
Packaging reduction refers to the systematic reduction of packaging materials by optimizing design, material selection and packaging structures. The aim is to minimize the consumption of resources while maintaining the protective and transport function of the packaging.
What methods are there for reducing packaging?
The most important methods include material substitution with lighter alternatives, design optimization for more efficient use of space, elimination of superfluous packaging layers and the development of innovative packaging concepts. Life cycle assessments support the evaluation of various options.
How do you measure the success of packaging reduction?
Success is measured by KPIs such as weight and volume reduction per product unit, cost savings, CO2 reduction and recycling rates. In addition, quality indicators such as transport damage and customer satisfaction are monitored to ensure that functionality is maintained.
What are the risks of reducing packaging?
The main risks include product damage due to inadequate protection, loss of quality due to excessive material reduction and compliance violations for regulated products. Supply chain dependencies and initial investments in new technologies pose further challenges that need to be addressed through systematic risk management.
.png)
.png)
.png)
