Running a high-volume fulfillment center comes with constant pressure to improve efficiency, cut costs, and keep customers happy. When it comes to packaging, even small changes can feel overwhelming, especially when considering a shift to sustainable materials. The good news? Transitioning to eco-friendly packaging doesn’t have to be complicated.
This article will give you a great start in scaling sustainable packaging, covering:
By breaking the process into manageable steps, you’ll see how achievable the switch really is, and gain clarity on which teams and partners to involve for the best results.
One of the easiest ways to introduce eco-conscious practices is by choosing outer packaging that actually fits the merchandise. Nearly every customer has experienced the frustration of receiving a tiny item shipped in an oversized box, a wasteful and avoidable mistake.
But oversized packaging isn’t just frustrating for customers, it’s costly for e-commerce vendors and fulfillment centers too. Excess outer packaging, like shipping boxes and envelopes, wastes gross material. It also increases the amount of void fill required to keep products secure in transit. The problem is even worse when that void fill consists of plastic air pillows or other synthetic materials that can’t be recycled or composted, adding to both environmental impact and disposal costs.
The goal is to collect a shipping container that’s just large enough to include a bit of void fill or other cushioning material to keep items from rubbing against each other or against the sides of the box. This approach not only minimizes material use but can also lower shipping costs, whether your carrier charges by weight or by dimensional pricing.
Whenever possible, the outer shipping container, whether a box or envelope, should be made of recyclable or reusable materials. We’ll take a closer look at these sustainable options in the next section.
The next step is to review your packing materials and identify where the most waste occurs. Many fulfillment centers rely heavily on plastic bubble or air pillows to protect products in transit. While effective, these synthetics are rarely recyclable and often end up in landfills.
The goal is to eliminate these synthetic packing materials and replace them with alternatives that are sustainable:
Plastic, foam, and many other inorganic packing materials are harmful to the planet, including animals and humans. Unlike HexcelPack’s kraft paper solutions, these materials can’t be composted or recycled curbside, so they typically end up in landfills where they take decades, if not centuries, to decompose.
When plastic breaks down, whether as dumped refuse or litter, it leaves behind toxic chemicals and microplastics—tiny bits of plastic that enter living beings, including humans, through precipitation, drinking water, and the food chain. These nanoplastics are linked to dementia, cardiovascular disease, respiratory problems, and reduced fertility.
Growing awareness of these risks is pushing both consumers and governments toward sustainable alternatives. States like Oregon and organizations such as the European Union have already enacted legislation requiring recyclable and eco-friendly packaging. If your business ships to these areas, or serves younger, sustainability-minded customers, adopting paper-based packaging is both a compliance measure and a brand-building opportunity.
Another type of packaging that sometimes overlaps with sustainable packaging is reusable packaging. These products are often resealable envelopes designed to simplify returns. Typically, they feature a second adhesive strip so the same envelope can be closed again and sent back to the retailer. Reusable packaging is especially popular in the retail clothing industry, where “try-before-you-buy” programs and clothing rental companies need a convenient way for customers to return items.
Many reusable envelopes are made of plastic or similar inorganic materials in order to get as many uses as possible from them. However, paper-based alternatives are a more eco-friendly choice. While they may not last through as many cycles, they can be easily recycled after use, reducing long-term environmental impact. Another practical option is to include a second paper envelope in the original shipment for returns. This approach is especially useful for rental items, which must be sent back regardless, and ensures the return process remains simple while staying aligned with sustainability goals.
For a small business, switching to entirely sustainable packaging all at once might be an option. But it may not be feasible to replace all your interior packing materials with sustainable options right away. You may need to work through existing inventory, or adjust your dispensing equipment and workflows before making a complete change.
That’s why phasing in sustainable packaging across a planned timeline is often the best approach. For example, you might begin by replacing outer packaging and product wrap first, then transition to sustainable void fill a month or two later.
The key is to create a clear plan. Align purchasing schedules so you stop ordering plastic or foam while ensuring sustainable alternatives are on hand before they’re needed. A long-term calendar can help map out each step of the transition.
In larger fulfillment centers, this process will require cross-functional collaboration, from management and accounting to purchasing teams and floor staff. By phasing in changes strategically, you can minimize disruption while steadily moving toward fully sustainable packaging.
If your fulfillment center manages orders for multiple clients, adopting sustainable packaging requires their participation as well. Any changes you make will directly affect how their products are presented, shipped, and received, so securing their buy-in is essential.
The good news is that the reasons to switch to sustainable packaging listed above are quite compelling. And from a business perspective, there is greater efficiency in choosing sustainable paper packaging like HexcelPack products. The innovative slit-paper design of HexcelWrap® product wrap, HexaFil™ void fill, and HexcelStretch™ pallet wrap offers superior cushioning for products and improved bulk load stability. This reduces breakage and wear on merchandise, resulting in fewer returns and exchanges for damage.
The final step in scaling sustainable packaging for your fulfillment center is letting people know about the change. Most people interacting with your packaging are recipients of the products you ship, so it’s essential they know how to properly dispose of or reuse the materials.
Include a clear note on receipts, merchandise tags, or other printed materials inside the package indicating which components are recyclable or compostable. This prevents customers from discarding eco-friendly materials in the trash simply out of habit.
And you don’t want to print separate content about the switch to sustainable packaging, as that would be wasteful. Instead, add a line or two informing customers on printed receipts or merchandise tags. In fact, it’s always great if you can make everything inside the parcel sustainable, eliminating plastic bags and other packaging that’s not recyclable. Another option is to use a paper-based sticker or paper-based tape printed with your message about sustainability.
If you’re ready to make the change to sustainable packaging at your fulfillment center, the experts at HexcelPack are here to help. We can assist with creating a timeline, supplying the right materials, and ensuring dispensing works for your needs.
Start with a conversation with our team and discover a customized approach that makes scaling sustainable packaging simple, efficient, and effective.