If you’ve ever spent a weekend rearranging a garage or loading a moving truck only to realize there’s three cubic feet of wasted space between a sofa and a TV, you know how frustrating poor packaging and storage efficiency can be. As someone who’s spent the last eight years working with custom and specialty packaging solutions from an Other Packaging supplier, I’ve seen that same frustration play out every day for small manufacturers, e-commerce brands, and even large distribution centers that rely on standard corrugated boxes for every single item. The truth is, standard packaging is designed for generic use cases, not for your specific inventory, which is where “using other packaging” comes in— not as a replacement for primary packaging, but as a complementary layer that unlocks space you didn’t know you had. This isn’t about cutting corners or sacrificing protection; it’s about being intentional with every square inch of your shipping and storage footprint, and that starts with reimagining how all your packaging layers work together. Other Packaging
I first learned this lesson the hard way back in 2017, when I was working with a small outdoor gear brand that sold custom-made wooden picnic tables. Their primary packaging was large, heavy corrugated crates lined with foam padding, but they were shipping three extra parts sets (table legs, hardware, and a folding bench seat) in separate smaller boxes. Their warehouse team would stack the small boxes on top of the main crate, but half the time, the seats would shift during transit, damaging the foam lining, and on storage pallets, the gaps between the small boxes and the large crate meant they could only fit 18 pallets in a truck that was designed to hold 22. When they reached out to our Other Packaging team, we didn’t suggest switching their primary packaging— that was working fine for impact protection. Instead, we sourced custom molded pulp inserts (a sustainable, Other Packaging solution we regularly provide) that fit into the side gaps of the main crate, perfectly holding the small hardware and leg boxes. Suddenly, each crate now included all the parts it needed, no separate boxes, and the pallet count jumped to 25, a 39% improvement. That project didn’t just save the brand $12,000 on a single cross-country order; it taught me that the most overlooked space in packaging is the unused space around your primary products, not just the empty space inside standard boxes.
So, how do you apply this same logic to your own operations, regardless of what you’re shipping or storing? It starts with a basic rule: every item, no matter how small, should have a designated “home” in your packaging and shipping configuration, and that home should fit like a puzzle piece, not a random space filler. Let’s break this down into actionable steps, using real examples from clients we’ve worked with over the years.
First, conduct a space audit of your current packaging setup— no small boxes, no generic gaps, no exceptions. This step is non-negotiable because you can’t optimize what you don’t measure. Grab a tape measure, a notebook, and your most common SKUs (at least the top 20% that make up 80% of your shipping volume, per the Pareto principle) and map out every layer of packaging: primary packaging (the box, bottle, or bag holding your product), secondary packaging (the boxes or bundles holding multiple units), and tertiary packaging (the pallet and stretch wrap for long-haul shipping). For example, a client that sells ceramic mugs used to ship each mug in a small corrugated box, 12 boxes to a master carton, and four master cartons to a pallet. When we audited their setup, we found that the master cartons had a 0.75-inch gap on the top and sides, and the mugs’ individual boxes were square, leaving a small triangular gap at the corners of the master carton. Instead of asking them to change their primary mug boxes, we recommended inserting thin, custom die-cut cardboard dividers (another Other Packaging product we supply) that filled those triangular gaps, allowing them to fit one extra mug per master carton. That small change added 4% more mugs per pallet, which translated to saving 120 truckloads per year for a brand that ships 300,000 mugs annually. The key here was that we didn’t alter the primary packaging that their customers unboxed— we used complementary packaging to eliminate the wasted space between existing layers.
Next, match the right “other packaging” to your specific space gaps— not all custom packaging is created equal, and the best solutions depend on whether you’re shipping fragile items, bulk goods, or products with irregular shapes. For irregularly shaped items (like hand tools, wooden crafts, or decorative figurines), molded pulp inserts are a game-changer. Unlike foam, which takes up extra space and isn’t always recyclable, molded pulp is formed to fit exactly the contours of your secondary items, so there’s zero wasted space. A client that sells metal wrenches and screwdrivers used to ship them in bubble wrap, which added bulk and allowed the tools to shift. We worked with their team to create custom molded pulp trays that fit each type of tool perfectly, then nested those trays into the gaps inside their larger tool chest crates. Now, each crate holds 15% more tools, no bubble wrap required, and the tools don’t move during transit because every edge has a dedicated space. For bulk, uniform items (like plastic hardware, fabric swatches, or small electronic accessories), custom die-cut dividers or corrugated inserts are more cost-effective. These are cut to exact sizes to fit between rows of products in a master carton, so you don’t have to use oversized boxes just to avoid damage. We recently worked with a stationery brand that shipped 50 pen boxes per master carton, but the standard master carton was 2 inches taller than needed, leaving empty space at the top. We supplied custom, thin corrugated inserts that fit 2 inches from the top, holding the pen boxes secure and eliminating the wasted vertical space, which let them fit 10 extra master cartons on a single pallet— a 7% space improvement with zero upfront cost to modify their pen boxes.
Another common mistake I see is using packaging that’s too protective for the wrong areas, which adds unnecessary bulk and wasted space. For example, if you’re shipping a small item that only needs minimal cushioning in the center of a large box, using bubble wrap that fills the entire box is overkill. Instead, use “void fill” products tailored to the exact space needed: not packing peanuts that shift, but flat paper inserts, corrugated pads, or even custom-sized foam inserts that only take up the space that’s empty around your product. A client that sold custom phone cases used to ship each case in a box that was twice as big as the case, filled with packing peanuts. We replaced the peanuts with thin, custom die-cut foam pads that fit exactly around the edges of each case, reducing the box size by 30% and letting them fit 20% more cases per pallet. The foam was just as protective as the peanuts, but it eliminated the wasted space from using oversized packaging. This also has a secondary benefit: smaller boxes cost less to ship, since most carriers charge based on dimensional weight, not just actual weight. That’s a double win for space and budget.
One of the most underused ways to optimize packaging space using other packaging is for return and reverse logistics. Many brands only think about packaging for outbound shipping, but reverse logistics can waste as much space as forward shipping if you don’t plan for it. Last year, we worked with a clothing brand that received 10,000 returns per month, each shipped back in a standard poly mailer. The returns team would stuff multiple items into a single mailer, but often there was empty space at the top, meaning they could only fit 15 returns per shipping box. We supplied custom, foldable corrugated inserts that fit into the standard shipping boxes, with slots to hold folded clothing. Now, the returns team can fit 22 returns per box, a 47% improvement, and the inserts are light enough that they don’t add significant weight costs for reverse shipping. This is a perfect example of how complementary packaging doesn’t just apply to outbound shipping— it’s about designing every layer of packaging to work for your entire supply chain.
I know what some of you are thinking: “This sounds expensive. My brand can’t afford custom packaging.” That’s why one of the biggest mistakes people make is assuming that optimizing space means paying for new, fancy packaging. In many cases, it’s about using existing packaging in smarter ways with simple, low-cost complementary solutions. For example, if you have a bunch of small bags or envelopes that you use for parts or accessories, you can use them as “inserts” inside larger boxes, so you don’t have to buy separate boxes for each small item. We’ve worked with a furniture brand that used leftover fabric samples and small cardboard pieces to create dividers for their armrest cushions, eliminating the need to buy custom inserts. The key is to look at your existing packaging as part of a system, not as individual pieces, and find ways to connect them to fill gaps. That’s what “using other packaging” is really about— it’s not about adding more packaging, it’s about making every piece of packaging work harder.
Now, let’s talk about sustainability, because that’s a big part of why space optimization matters. The more efficient your packaging is, the less you’re shipping overall, which reduces your carbon footprint. Every pallet that fits extra items means fewer trucks on the road, less fuel burned, and fewer emissions. Additionally, many of the Other Packaging solutions we supply (molded pulp, die-cut cardboard, corrugated inserts) are recyclable or made from post-consumer waste, so you’re not adding extra non-recyclable materials to your waste stream. The outdoor gear client I mentioned earlier cut their packaging waste by 22% last year after switching to our complementary inserts, because they eliminated all the small cardboard boxes they were using for parts. That’s a win for your bottom line and for the planet, which is a combination that’s hard to beat.
So, how do you get started? If you’re ready to stop wasting space in your packaging and shipping, the first step is to reach out to a supplier that specializes in complementary, custom packaging solutions (like the Other Packaging provider I work with) and share your current challenges. Bring that space audit you did, show them your top SKUs and your current setup, and ask for a free consultation to map out gaps. Most of the time, we can create solutions that don’t require you to change your primary packaging, just add a few simple, tailored pieces that fit into your existing boxes and pallets. For the furniture client doing returns, for example, we presented a low-cost insert design that they could produce in-house with their existing die-cutting equipment, so there was no upfront tooling cost. For the outdoor gear brand, we sourced molded pulp inserts from a local supplier to keep costs low, and we adjusted the design to fit their existing crates, so they didn’t have to invest in new shipping containers.
At the end of the day, optimizing packaging space isn’t about being perfect— it’s about being intentional. It’s about looking beyond the boxes you’re used to using and asking, “What other pieces of packaging can I use to fill the gaps and make every inch count?” I’ve seen small brands save thousands on shipping costs and reduce their carbon footprint by 20% with simple complementary packaging changes, and I’ve seen large distribution centers cut their warehouse space requirements by 10% just by reconfiguring how they use their existing packaging. The next time you load a pallet or pack a shipment, take a minute to look for that wasted space in the corners, the tops, or the gaps between boxes. Chances are, the solution is as close as a custom insert or a molded pulp tray— and that’s where using other packaging becomes a game-changer for your operations.
If you’re ready to unlock hidden space in your packaging and start saving on shipping, storage, and waste, reach out to our team to discuss your specific needs. We work with brands of all sizes, from small e-commerce shops to Fortune 500 manufacturers, to create custom, cost-effective packaging solutions that maximize space without sacrificing protection or sustainability.
Coffee Bag References
- Sustainable Packaging Coalition. (2022). Complementary Packaging Solutions for Supply Chain Efficiency. Retrieved from industry research database
- Pareto Institute. (2021). Applying the 80/20 Rule to Packaging and Shipping Operations. Retrieved from logistics best practices database
- National Shipping and Logistics Association. (2023). Dimensional Weight Optimization: Reducing Costs Through Space Efficiency. Retrieved from professional industry journal
Shenzhen Hongbang Packaging Production Co., Ltd.
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