Do not average the catalog
Split by product shape, fragility, order quantity, carrier lane, and return risk. One blended average can hide the SKU group where flexible packaging actually works.
Buyer checklist
Procurement Notes For Flexible Packaging Tests
Use these notes to keep a packaging change measurable. The goal is not to replace every carton. It is to identify the order segments where a smaller or faster package is genuinely safer and cheaper.
Run carton and mailer side by side
Hold a carton control group during the first pilot so damage, labor, and customer-service deltas can be measured against the current process.
Measure touches, not just material
Count folding, taping, scanning, insert placement, and exception handling. Labor savings often decides the business case.
Packaging has a second trip
If the package is likely to be reused for returns, include tear strips, reseal features, and label placement in the test criteria.
Lane mix matters
DIM savings vary by carrier, service, and zone. Compare actual invoice detail after the pilot, not only quoted rate-card math.
Create a packaging rule
After the test, turn the finding into a pack rule by SKU family, order quantity, and exception condition so the savings are repeatable.