Is your packaging costing more than it should? Why a packaging audit matters in 2026
Packaging is often treated as a fixed operational cost… until something goes wrong.
Rising material prices, product damage, warehouse inefficiencies and Extended Producer Responsibility (EPR) reporting requirements are forcing many businesses to reassess how their packaging performs.
If your packaging specifications have not been reviewed for several years, a professional packaging audit can uncover significant opportunities to reduce costs, improve performance and strengthen compliance.
What Is a packaging audit?
A packaging audit is a structured review of how packaging is specified, applied and managed across your operation. No two audits are the same. The scope and focus areas are agreed with you in advance, so the review is shaped around what matters most to your business, whether that is cost reduction, throughput, damage, compliance or a combination of all of these.
It looks beyond unit price and examines:
• Material performance in real working conditions
• Packing line efficiency
• Damage rates and returns
• Waste and recyclability
• Storage and stock control
• EPR exposure and reporting complexity
The aim is simple: to help you pack smarter, reduce waste and control your total packaging cost.
Why packaging audits are increasingly important
- Rising costs
Even small inefficiencies in stretch film usage, carton specification or void fill selection can add up to significant overspend over time.
- Extended Producer Responsibility (EPR)
From 2025, many businesses are responsible for reporting packaging data and paying fees based on recyclability. Poor material choices can increase compliance costs unnecessarily.
- Product damage and returns
Incorrectly specified packaging often leads to hidden costs in rework, customer dissatisfaction and transport inefficiencies.
- Throughput and labour efficiency
Packaging impacts packing speed, workflow and consistency more than many organisations realise.
A structured review highlights where improvements are commercially meaningful.
What does a packaging audit typically review?
While every audit is tailored, key areas include:
• Cartons, film, tape, pallets and void fill
• Packing machinery and pallet wrapping systems
• Application methods used by staff
• Waste streams and recycling practices
• Storage and stock rotation
• Damage records and returns
• EPR classifications (household vs non-household)
Importantly, it examines the true cost of packaging – not just purchase price, but labour, damage, storage and compliance implications.
When should you consider one?
A packaging audit is particularly valuable if:
• Damage levels are increasing
• Costs have risen without clear explanation
• Your supplier has not reviewed specifications recently
• You suspect materials may be overspecified
• EPR reporting feels unclear
• Sustainability targets are becoming harder to meet
In many cases, packaging has evolved incrementally over time without strategic review.
The value of an independent review
An experienced packaging partner brings technical, operational and sustainability insight to the table.
At Samuel Grant Packaging, our packaging audit combines:
• Operational observation
• Material optimisation
• EPR awareness
• Sustainability expertise
• Practical implementation support
The outcome is not just a list of recommendations, but a clear pathway to measurable improvement.
Implementation and ongoing support
A Samuel Grant packaging audit does not end with a report. Once changes are agreed, we stay involved. We support trials, train staff where needed, and revisit regularly to track performance and ensure improvements are delivering the expected results.
We also provide ongoing EPR data reporting and internal stock reporting, as well as stock checks where required. Where it helps, samples and prototypes of recommended materials can be provided so changes can be evaluated properly before any decision is made.
Packaging should protect your product and your margins. If you are not confident your current packaging is the most cost-effective, sustainable and compliant solution available, it may be time for a fresh look. Samuel Grant Packaging is not just a supplier in this process; we are a working partner throughout it.
To discuss a packaging audit, speak to your local Samuel Grant Packaging representative.
