Optimizing packaging size at the category level is choosing a set of specifications that fits multiple order groups. The problem lies not only in a smaller box, but also in the number of sizes that need to be managed and how employees choose the right one. This is the improvement direction SquareBag proposes for the 2026 plan.
Compare the single group with the current sizes
Record the type of application, size after protection, weight and fragility level. Comparing with the box in use to find the group often requires adding more inserts or using a box that is too large.
Choose a limited trial category
| Group | How to get started |
|---|---|
| Popular single | Try on a suitable size and measure the operation |
| Stable combo | Design how to arrange and insert in sets |
| Rare application | Consider the size of the fallback, avoid adding code too early |
Start from a group with a stable quantity and clear closure. In rare cases, a backup size can be used if protection is still achieved. Avoid creating your own code too early when there is not a strong enough need.
Select the index to compare before and after
Track the amount of materials, labor, delivery fees, damage and inventory. Compare the same single group to see if the benefits of a smaller box are offset by management costs.
If three sizes cover the majority of the order but a tall order requires its own size, a spare size can be kept. Continue collecting data before expanding the category.
Convert in batches
Transfer in batches and use up appropriate stocks when possible. Finalize size selection table, stacking direction and version of instructions. When products change, check the size system before adding a new box.
Is PPWR required to implement this program immediately?
Internal programs need to be distinguished from PPWR obligations which have their own scope and schedule. See article PPWR clearance limit when preparing EU documents.
Send SquareBag a representative group of orders and the current box list to discuss the sample testing roadmap.
Explore SquareBag packaging project or Exchange specifications with SquareBag.
See Trends 2026 group