How We Reduced Packaging Waste Across Our Warehouses

Over the past year our warehouse team redesigned outbound packaging standards to cut cardboard usage by roughly 30% without compromising static-sensitive handling requirements. The project started as a cost-reduction exercise but quickly became one of our most visible sustainability wins once we saw the scale of the reduction across our shipping volume.

Right-sized cartons eliminated the excess void space that drove both material waste and damage-in-transit claims. Reusable dunnage for repeat freight lanes — mostly our regular manufacturer-to-warehouse routes — cut single-use packaging almost entirely on those lanes. A shift to recycled void-fill for the remaining outbound orders was the third major lever, replacing foam peanuts with a paper-based alternative that's fully recyclable at the customer end.

We're rolling the same standards out across our remaining distribution centers this year, with the goal of hitting a consistent packaging footprint company-wide rather than having our flagship facility carry the sustainability gains alone.