Packaging for E-commerce: Meeting the Sustainability Challenge

12 May 2025

The boom in online shopping in the last 10 years has completely changed how we buy things, and naturally, how businesses package them. It’s easy to see why. Next-day delivery, global shipping, packages landing right on our doorsteps, it's the norm now. Behind this convenience, packaging has been working overtime to keep up. But as more and more boxes arrive, we're all paying closer attention to the packaging itself.

 

Today's shoppers expect more than just speed; they value responsibility. They want packaging that protects the item inside and feels good to open, whilst remaining easy on the planet. For e-commerce businesses, meeting all these needs can feel like a real balancing act.

To meet these challenges, we partner with a huge number of online retailers and fulfilment centres, helping them navigate this balance between solid protection, great presentation, and genuine sustainability. Here’s a look at how we approach it.

 

The E-commerce Packaging Challenge: Volume, Waste, and What Customers Expect
A photorealistic image of a stack of oversized cardboard boxes with excessive void fill spilling out surrounded by crumpled plastic and paper packaging materials on a white background-1

E-commerce packaging has a tougher job than traditional retail packaging. It needs to withstand a complex journey through automated warehouses, sprawling distribution networks, and the final delivery mile. It must keep the product safe, look presentable upon arrival, and be simple for the customer to open, recycle, or even use for a return.

 

The reality, though, is that often packaging has been 'overdone' just to be safe, leading to too much void fill, boxes that are far too big, and unnecessary plastic. This doesn't just waste materials and increase shipping costs; it can also damage how customers see a brand's commitment to the environment.

 

And customers are paying attention. A recent study highlighted that over 70% of online shoppers feel packaging reveals how much a brand cares about sustainability. The message is undeniable: sustainable packaging isn't just about logistics anymore. It's fundamental to the brand itself.

 

Making Smart, Sustainable Packaging Choices for Online Retail
A photorealistic selection of sustainable packaging materials including compact boxes paper wraps and recyclable mailers laid out neatly on a white background

Choosing sustainability in e-commerce packaging doesn't mean sacrificing protection. It's about selecting the right solutions that do their job effectively while minimising waste and environmental footprint.

 

Here are some key areas where we work with e-commerce businesses to find smarter, sustainable solutions:

 

  • Right-sizing your packaging
    A small item inside a perfectly sized cardboard box with no void fill next to a larger empty box to contrast on a clean white background-2
    Using packaging that fits the product snugly is crucial. It cuts material waste and significantly lowers shipping costs and CO₂ emissions. Think beyond just standard boxes, options like our versatile book wraps for flat items, robust postal boxes designed for secure mailing, and custom-sized Durabox™ cartons help businesses ship efficiently and sustainably, minimising the need for excess void fill.

  • Choosing eco-friendly void fill
    A closeup photorealistic shot of ecofriendly paper void fill inside a partially open cardboard box showing recyclable icons and materials on a white background

    It really is time to move beyond plastic air pillows or foam peanuts. Innovative paper-based systems are the way forward. Whether it's the cushioning protection of grip®’s Paperflex, expanding paper void fill dispensed on-demand, or other recyclable paper options, these are becoming standard in eco-conscious fulfilment centres, protecting goods without the plastic waste.

  • Making it easy to recycle and return
    A cardboard postal box with tear strips and a resealing adhesive strip visible next to a paper mailing bag with a recycling logo on a white background

    Customers appreciate packaging that considers the end-of-life journey. Features like easy-open tear strips and double adhesive strips for hassle-free returns (often found on our postal boxes and e-commerce mailing bags) make a big difference. Opting for clearly recyclable materials, including sturdy paper mailing bags as an excellent alternative to plastic poly mailers, gives customers peace of mind. We help design packaging that works beautifully both ways.

  • Considering sustainable closure
    Rolls of paper tape and wateractivated tape beside a sealed cardboard box showing the ecofriendly sealing options clearly placed on a white background-1

    Even the tape makes a difference! Switching to water-activated gummed paper tape or self-adhesive paper tapes eliminates plastic tape, reinforcing the package's recyclability and enhancing the sustainable unboxing experience.

  • Optimising bulk shipments
    A single pallet wrapped with a layer of clear stretch film with ecofriendly labels and compact packaging visible isolated on a white background-1

    For palletised goods moving through the fulfilment network, our Sigmawrap™ pre-stretch film remains vital. It can cut plastic usage by up to 50% compared to traditional films, securing loads effectively while significantly reducing plastic consumption.

Where Logistics and Sustainability Connect
A photorealistic flatpacked cardboard box beside a spaceefficient automated packing system all on a white background-1

Sustainable thinking extends beyond just the packaging materials; it includes how packaging functions within your logistics. Bulky or excessive packaging uses valuable space in warehouses and delivery vehicles, increasing operational costs and fuel emissions.

We closely analyse the whole supply chain via packaging audits, helping e-commerce clients to free up warehouse space, speed up packing lines, and get more packages into each delivery vehicle, boosting both sustainability and overall performance. Simple changes like adopting automation for repetitive tasks or switching to space-saving flat-packed formats can yield big results in high-volume settings.

Certification, Compliance, and Earning Customer Trust

A collection of packaging items each marked with recycling symbols arranged professionally against a white background-1

Accountability is key to sustainability. That's why we clients navigate environmental regulations and meet their ESG (Environmental, Social, and Governance) goals with certified packaging solutions. Our FSC®-certified options and ISO 14001-accredited processes provide confidence to both businesses and customers that sustainability commitments are genuine.

Creating Better Brand Moments
A premiumlooking ecofriendly package halfopened to reveal a branded insert and natural materials inside representing a satisfying unboxing moment on a white background-2

And let’s not forget that crucial unboxing moment! For many online brands, the package is the very first physical interaction with the customer. Sustainable packaging does not have to mean boring or basic. Through thoughtful design and appealing, sustainable materials, brands can make a fantastic first impression that aligns perfectly with their values.

 

We love helping brands ensure their packaging perfectly reflects their story – one of efficiency, responsibility, and genuine customer care.

We’re here to help you find the right approach for your unique business, one that integrates smoothly into your supply chain, supports your sustainability goals and helps you build stronger connections with your customers.

 

Contact us today to explore solutions tailored just for you. You can send us a message, email sales@allpack.uk.com, or call 01543 396 700.

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