Can Reviewing Packing Materials Boost Profits? Crucial Selection Tips for Mall Operators

In e-commerce mall operations, "cost optimization" is just as critical as increasing sales. Among these costs, the daily expense of "packing materials" is often overlooked, yet it holds significant potential for drastically improving profit margins. Packing materials may seem trivial, but they are not. A simple "review"—such as reducing the size by one centimeter or changing a single sheet of material—can create a profit difference of hundreds of thousands, or even millions of yen annually. This article explains strategic points for material selection that cut costs while maintaining brand value.

Various eco-friendly packaging materials including cardboard boxes, paper tape, and protective cushioning arranged on a clean wooden surface, representing logistics optimization and cost-effective shipping strategies for e-commerce businesses.

1. The Impact of Reduced Packing Size on "Freight Costs"

The greatest benefit of reviewing packing materials lies not in reducing the unit cost of materials, but rather in the "optimization of shipping freight costs." Since many carriers set rates based on size (sum of length, width, and height), even a slight excess in size can squeeze profits.

For example, if you continue to ship items in size 80 boxes when they could fit in size 60, you incur a loss of 100 to 200 yen per shipment. If you ship 1,000 items a month, that calculates to a loss of over 1.2 million yen annually. Creating "custom boxes" tailored to your product's shape requires an initial investment, but it is overwhelmingly advantageous in terms of long-term total costs.

A high-tech automated warehouse system measuring package dimensions with precision sensors to optimize shipping space and reduce logistics costs, illustrating the intersection of technology and physical packaging efficiency.

2. Balancing Material Costs and Brand Experience

While prioritizing cost reduction is important, you must not create a "disappointing unboxing experience." Flimsy bags or cushioning that is too large for the product can damage your brand's reliability.

The key to smart selection is to keep the exterior (like cardboard boxes) simple to keep costs down, while focusing on the "interior" and "thank you cards" that catch the eye the moment the package is opened. This allows you to increase Customer Lifetime Value (LTV) while lowering total material costs.

3. Benefits of Introducing Eco-Friendly (Sustainable) Materials

In the EC market of 2026, consideration for the environment is changing from a "nice-to-have" to a "must-have." Initiatives such as switching from plastic cushioning to paper, or adopting biomass material bags, lead to evaluation as an "excellent store" within the mall.

Especially in major malls, the number of users choosing low-environmental-impact shipping options is increasing, making sustainable packaging a powerful weapon for acquiring new customers.

Close-up of eco-friendly packaging details showing recycled paper texture and natural hemp twine, symbolizing a brand's commitment to sustainability and high-quality customer experience in modern retail.

4. Data-Driven Effects of Material Review

The graph below shows the Profit Awareness trend (simulation) per order when an EC shop reduced the packing size by one rank and switched to bulk purchasing of materials. By rethinking material costs as variable costs rather than fixed costs, there are cases where the operating profit margin improved by 5%.

FAQ

Q. Can I create custom-designed boxes in small quantities?
A. Recently, there are an increasing number of on-demand printing services that allow orders from small lots (50-100 units). We recommend testing with one size that fits your best-selling products.
Q. I'm worried about damage if I reduce cushioning. How should I handle this?
A. The key is not just to reduce the amount, but to change the material. For example, switching from loose-fill cushioning that just fills gaps to film cushioning that secures the product can reduce material usage while enhancing protection.

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Summary

Reviewing packing materials is not just a simple cost cut, but an "investment" that can simultaneously achieve improved delivery efficiency, strengthened brand image, and reduced environmental impact. Start by taking stock of the delivery sizes of your main products and current material unit costs. Small changes will surely return as significant profits in the future.

Published: January 15, 2026 / Author: Osamu Yasuda

References

  • [1] Japan Logistics Society: Survey on Correlation between Packing Size and Freight in EC Logistics
  • [2] Ministry of Economy, Trade and Industry: Report by the Study Group on Realizing Sustainable Logistics
Disclaimer: This article is for informational purposes only and does not substitute for professional advice. It does not guarantee specific results.