How Box Optimisation Can Help Minimise Your EPR Liability
Extended Producer Responsibility (EPR) is reshaping the way businesses think about their packaging. As brand owners and distributors, you are now more accountable for the environmental impact of the packaging you place on the market. This means your packaging choices – from design to material make-up – directly influence the financial contributions your business will need to make under the new regulations. If you would like to know more about EPR, take a look at our in depth guide.
Packaging is more than just a way to protect your products. The right solutions can reduce cost, cut carbon and now, crucially, minimise your EPR liability. One of the most effective ways to achieve this is through the optimisation of corrugate packaging, specifically the box styles you use and the materials they are made from.
In this blog we’ll uncover how box optimisation can minimise the cost of EPR, as well as the positive knock-on effect to your supply chain.
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Why corrugate boxes matter under EPR
Corrugate cardboard remains the backbone of the packaging industry. It’s lightweight, strong, versatile and widely recycled – qualities that make it a go-to choice for shipping cartons, ecommerce packaging and shelf-ready packs.
However, EPR fees are calculated on both the weight and recyclability of the packaging material. Even small inefficiencies in box style or material composition can lead to significantly higher costs over the course of thousands – or even millions – of units.
By reassessing the design and board grade of your corrugate packaging, you can ensure you’re using the most resource-efficient solution possible. This not only keeps your EPR liability under control but also delivers knock-on benefits across your supply chain.
Optimising box styles to reduce material use
One of the biggest opportunities to minimise EPR liability is by reviewing the style of corrugate box you use.
Traditional box designs are not always the most material-efficient option. In many cases, alternative designs can achieve the same level of protection with less board.
A redesign could also deliver a reduction in the use of other packaging materials, like the amount of void-fill required, tape free sealing or removal of internal fitments to hold products in place.
By reviewing your box range and redesigning into a more optimised style, you can significantly reduce the amount of board used, depending on the application. Under EPR, this translates directly into reduced liability – because you’re paying fees on fewer grams of packaging per unit.
Choosing the right corrugate material make-up
Beyond box style, the material composition of your corrugate packaging has a major role to play in EPR liability.
Corrugate board comes in different grades and fluting profiles, from lightweight single wall to heavy-duty double, or triple, wall options. While heavier grades are essential for certain products, many businesses can default to “over-specifying” – using a stronger (and therefore heavier) board than necessary.
Through professional analysis of product weight, fragility and shipping conditions, it’s often possible to move from double-wall to a lighter single-wall board without compromising performance. That change can further reduce packaging, directly reducing your EPR obligations.
How RAM will shape future material choices
As EPR evolves, Recycling Material Assessment (RAM) is set to play a pivotal role in how materials are valued. Packaging that scores poorly under RAM will attract higher fees, making recyclability a key consideration in every packaging decision.
Corrugate is well positioned, as it is widely recycled in the UK. However, material choice still matters. Boards with wax or plastic coatings, for example, are harder to recycle and may face higher charges. Similarly, using unnecessary mixed materials – such as laminated finishes – could reduce your recyclability score.
By proactively aligning your corrugate packaging with RAM standards now, you can future-proof your packaging portfolio against rising costs and regulatory pressure. To find out more about RAM and how it will affect your packaging choices, take a look at our in depth guide.
The supply chain benefits of packaging optimisation
The benefits of optimising corrugate packaging don’t stop at EPR. Reducing material weight and switching to more efficient box styles has a positive ripple effect across your supply chain.
Lower transport costs: Lighter packaging means reduced shipment weights. This can lower freight costs and allow you to fit more units per pallet or vehicle.
Reduced storage space: More efficient box designs often come flat-packed in smaller bundles. That means lower storage costs in your warehouse and less handling for your teams.
Faster packing times: Designs like crash-lock cartons are quicker to assemble, reducing labour time and boosting fulfilment efficiency.
When considered together, these savings can be substantial. Many of our customers find that the cost savings generated by optimised corrugate packaging outweigh their initial investment in packaging redesign.
Cutting CO₂e through smarter corrugate choices
Carbon reduction is another critical area where packaging optimisation pays off. Every gram of packaging material you remove reduces the carbon footprint of your supply chain.
Manufacturing lighter corrugate consumes fewer raw materials and less energy. Transporting lighter shipments reduces fuel use and emissions. Optimised packaging also tends to minimise void fill requirements, which means fewer additional materials are needed.
Switching to a lighter corrugate grade can reduce the carbon footprint of a single box. When multiplied across thousands of units, the CO₂e savings are significant, supporting your business’s net-zero targets while also demonstrating compliance with customer and regulatory expectations.
Why now is the time to act
EPR is not a short-term challenge, it’s a long-term shift in how packaging will be designed, measured and valued. Businesses that act now to optimise their corrugate packaging will be better positioned to minimise fees, reduce supply chain costs and deliver on sustainability targets.
At Macfarlane Packaging, our Packaging Optimisation service is designed to help you achieve exactly that. Using tools like our Packaging Optimiser with carbon measurement software, we analyse your existing packaging, identify opportunities to reduce material use and improve recyclability. Our state-of-the-art Innovation Labs redesign and test pack performance to meet the rigorous conditions of your supply chain. We offer tailored solutions that balance protection, cost and compliance.
Contact us today to arrange a free of charge packaging review.