Packaging audits tend to suffer from a perception problem. They sound time-consuming, expensive and slightly disruptive, like something that will produce a long report and very little practical change. In reality, most audits are far more grounded than that. Many are quick, focused, and quietly revealing in ways that catch teams off guard.

As you might expect, the biggest value rarely comes from sweeping redesigns. It usually comes from just spotting small mismatches between what packaging was designed to do and how it is actually being used day to day.

What a Packaging Audit Usually Covers

In reality, a packaging audit is less about theory and more about observation. It looks at what is being packed, how it is handled, where it travels, and what happens when something goes wrong. That usually means reviewing pack sizes, material specifications, void fill usage, damage rates, and how packaging performs during storage and transport.

Audits often also include a walk-through of packing lines or fulfilment areas, conversations with the people doing the packing, and a review of courier claims or returns data. Documentation matters too, especially where material composition, recycled content, or supplier traceability are concerned. It is not unusual for audits to highlight gaps between what is specified on paper and what is actually being ordered or used.

Common Issues That Tend to Surface

One of the most frequent results is over-specification. Boxes that were upsized years ago after a damage issue, void fill added as a precaution and never revisited, or materials specified heavier than necessary because availability once felt uncertain. None of these decisions are irrational in isolation, but as you might expect, over time they compound.

Inconsistent materials also show up regularly. Similar products packed in different ways, multiple board grades used without a clear reason, or packaging sourced from different suppliers that perform differently in transit. These inconsistencies increase cost and make regulatory reporting harder than it needs to be.

There is often a human element too. Packing teams develop workarounds to hit targets, which sometimes causes inefficiencies that never appear in process documents. Audits bring those realities into view without assigning blame, which is why they tend to be well received on the floor.

Audits and Regulatory Readiness

Regulation is playing a much larger role in packaging decisions than it did even a few years ago. Extended Producer Responsibility reporting, the UK Plastic Packaging Tax, and recyclability requirements all depend on having accurate, consistent information about materials and formats.

Audits help businesses understand whether their packaging data would stand up to scrutiny. It’s therefore not uncommon to find a lack of certainty around recycled content percentages, mixed materials that complicate reporting, or legacy formats that no longer align with current guidance. Identifying those risks early is far easier than reacting under pressure later.

According to WRAP, improving data quality around packaging materials is one of the most effective ways businesses can reduce both compliance risk and unnecessary cost

Why Small Changes Often Deliver Quick Returns

One of the more surprising outcomes of audits is how quickly they can pay for themselves. Cutting a box size for a high-volume SKU, removing needless void fill, or standardising materials across a product range quite often lead to immediate savings in transport, storage and labour time.

These are not dramatic changes. They are often just little adjustments that feel obvious in hindsight, which is precisely why audits are useful. They create space to step back from habits that have quietly become expensive.

Seeing Audits as Risk Reduction

Packaging audits work best when they are framed as a way to reduce risk rather than a hunt for savings alone. They reduce the risk of non-compliance, supply disruption, damage-related returns, and creeping inefficiencies that only become visible when costs rise elsewhere.

For most businesses, the question is not actually whether packaging could perform better. It is whether there is time to look before small issues become larger ones./

If you have not reviewed your packaging setup in a while, a focused audit can be a practical starting point. It often reveals where cost, compliance, and performance overlap in ways that are easy to act on. If you would like to explore what that might look like for your operation, we are always happy to talk it through. You can send us a message, email sales@allpack.uk.com, or call 01543 396 700 to discuss next steps.