Key Tips for Designing Sustainable Packaging

If you’re looking to reduce your environmental impact, meet changing customer expectations and keep control of operational costs, designing sustainable packaging is a great place to start. Your packaging doesn’t just protect what you sell - it speaks for your brand, influences buying decisions and plays a direct role in your environmental footprint.

From cutting waste and improving storage efficiency to lowering carbon emissions across your supply chain, the way you design and manufacture packaging can help you meet your sustainability goals without compromising performance or profitability.

Here we look at the practical ways you can make your packaging more sustainable - and how ASC Direct can help you get there with packaging that works harder for your business.

Use Recyclable Materials as Standard

Designing sustainable packaging solutions often begin with the materials themselves. Choosing recyclable packaging - such as corrugated cardboard, recycled paper or biodegradable board - means your boxes can be reused or reprocessed after use, keeping them in the circular economy. These are environmentally friendly options that require fewer raw resources, result in lower carbon emissions and are widely accepted in recycling infrastructure.

At ASC Direct, most of our materials are 100% recyclable. Our corrugated cardboard is also sourced from an FSC Certified paper supplier - meaning when you use our packaging, you're helping to protect the continued biodiversity of the world's forests.

Design To Reduce Waste From The Start

Packaging waste often starts at the design stage. Oversized or poorly fitting boxes don’t just look inefficient, they use more material than necessary, require additional filler and take up extra space during transport. This leads to increased emissions, higher costs and unnecessary use of plastic and paper. Even small inefficiencies in packaging dimensions can have a significant environmental impact when multiplied across large-scale deliveries.

That’s why box size and structure should be considered alongside materials when designing sustainable packaging. A well-fitted box minimises the need for void fill, improves pallet stacking, and reduces the volume of shipments, helping businesses lower both waste and carbon footprint.

To support this, we’ve created a Box Builder tool that lets you input the exact dimensions you need - making it easier to design made-to-measure packaging that performs better with less waste.

Simplify The Structure for a Cleaner Manufacturing Process

Sustainability in packaging design isn’t just about choosing eco materials - it’s about how easy the packaging is to produce, fill and recycle. Complex boxes with laminated layers, separate inserts or plastic windows create friction in the manufacturing process and at end-of-life. Simplifying your design can lead to more efficient production, fewer assembly steps and less confusion when it comes time to recycle. ASC Direct offers a wide range of single-material format shipping boxes that are easy to assemble and compatible with high-speed packing lines - ideal for companies looking to save on dispatch time, while contributing to environmental efforts.

Avoid Coatings and Mixed Materials That Hinder Recycling

Boxes that combine glass, foil, plastic films or laminated finishes often look premium but perform poorly in the recycling stream. Even small design choices can limit the recyclability of the entire package. The most effective eco-friendly packaging uses mono-material construction and simple finishes that still protect products and maintain a high-quality feel. At ASC Direct, we prioritise uncoated paper finishes and high-quality printing methods that enhance your packaging’s appeal while still offering the ability to cleanly recycle.

Keep Ink Coverage to a Minimum

Large swathes of ink, dark colour blocks and high-gloss finishes not only increase production impact - they can also complicate recycling. Lighter designs with smaller printed areas reduce ink usage and energy during manufacturing while still delivering a strong shelf presence. Even our stronger packaging, such as BDCM boxes, offers an ink-free and clean look that keeps your products secure while negating your carbon footprint.

Use Your Packaging to Communicate Your Values

Consumers are increasingly interested in the backstory of the products they buy. Packaging is your chance to communicate what you stand for and guide customers to reuse, recycle or dispose of the box properly. Clear messaging about the box’s sustainable materials, a QR code linking to your sustainability statement or even a small note about your manufacturing processes can make the difference between a passive experience and a memorable, values-led impression.

Design For Efficient Storage and Transport

Sustainability isn’t only about what a box is made of - it’s also about how it moves through the system. Lighter, more compact packaging lowers emissions during transport, reduces space requirements in warehouses and can extend shelf life by offering tighter seals or better fit. At ASC Direct, our boxes are built for efficiency, designed to minimise bulk and improve how products are stored, picked and shipped. We offer packaging across many industries, from food & drink to clothing, and electronics to arts & crafts.

Start Small and Scale Responsibly

Designing sustainable packaging doesn’t have to be a full-scale overhaul. Many companies begin with a single product or seasonal line - testing new materials, monitoring customer response and scaling gradually based on real feedback. At ASC Direct, our flexible ordering system allows you to purchase as few as 25 units. This gives you the freedom to experiment, prototype and refine your packaging strategy without generating excess or making premature bulk commitments. When you are ready to buy in bulk, we can serve you there too - by delivering discounted large-scale orders that minimise the impact of transport on your carbon footprint, while maximising your value for money.

Start Designing Smarter Sustainable Packaging Today

Ready to create packaging that supports your sustainability goals and strengthens your brand? At ASC Direct, we make it easy to design packaging that not only protects your products, but also reflects your values, reduces waste and adds impact where it matters.

With our Box Builder, you can customise every detail - from size and strength to finish and quantity - so your packaging fits perfectly and performs across the entire supply chain. We offer discounts on larger orders, and fast dispatch in under three working days - ideal for businesses that need reliable, scalable solutions without supply chain delays.

Whether you’re launching a new sustainable product or refining your existing packaging, we’ll help you build a solution that works for your budget, your timeline and your customers.

Get in touch by calling 0800 0731 126 or filling out our online contact form, and we will help you find the perfect bespoke packaging solutions for your business.

James Palfrey-Smith is the Commercial Manager at ASC Direct with extensive experience in both operations and sales. James is passionate about solving packaging problems, delivering fast customer support, and building lasting relationships. Outside of work, he enjoys outdoor activities like hiking and skiing. A fan of real ale and business podcasts, he continuously seeks personal and professional growth.

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