The Hidden Cost of Ordering Packaging Too Frequently

For many businesses, ordering packaging is simply another routine purchasing task. When stock runs low, another order is placed.

While this approach may seem convenient, ordering small quantities on a regular basis can often cost significantly more than ordering larger quantities less frequently.

The cost isn't just the price of the boxes themselves. Every order generates additional transport costs, administration, handling and production overheads that can quietly increase your overall packaging spend.

In this guide, we'll explore the hidden costs of frequent packaging orders and explain why buying in larger quantities can often deliver better value for your business.

In Short: Is It Cheaper to Order Packaging in Bulk?

In many cases, yes.

Ordering larger quantities can help reduce:

• Delivery charges

• Cost per box

• Administrative time

• Purchasing costs

• Production setup costs

• Risk of stock shortages

• Emergency deliveries

For businesses with predictable packaging requirements, bulk purchasing can reduce both costs and operational disruption.

Why Do Businesses Order Small Quantities?

There are plenty of good reasons.

Some businesses:

• Have limited warehouse space.

• Experience seasonal demand.

• Are unsure of future sales.

• Want to minimise stock holding.

• Believe smaller orders improve cash flow.

While these are all valid considerations, it's important to understand the hidden costs that frequent ordering can create.

1. Delivery Charges Soon Add Up

Every packaging order needs to be manufactured, packed and delivered.

If you place twelve small orders each year instead of four larger ones, you're likely to pay delivery charges three times more often.

Even where delivery is included within the purchase price, transport still forms part of the overall cost.

Reducing the number of deliveries can often reduce the total cost of supplying your packaging.

2. Small Orders Often Cost More Per Box

Every production run involves machine setup and preparation.

Whether a manufacturer produces 25 boxes or 1,000 boxes, many of the setup processes remain the same.

As production volumes increase, these fixed costs are spread across more boxes, reducing the cost per unit.

This is one of the main reasons larger packaging orders often provide better value.

3. Administration Costs Are Often Overlooked

Every order creates administrative work.

For each purchase, someone typically needs to:

• Raise a purchase order

• Obtain approvals

• Receive an order confirmation

• Process an invoice

• Arrange payment

• Book goods into stock

These activities all consume valuable staff time.

Ordering fewer, larger quantities can significantly reduce purchasing administration throughout the year.

4. Warehouse Teams Spend More Time Receiving Deliveries

Every delivery arriving at your premises requires time to unload, inspect and book into stock.

Multiple small deliveries increase:

• Goods-in processing

• Handling time

• Vehicle movements

• Administrative workload

Reducing delivery frequency can improve warehouse efficiency.

5. Emergency Orders Usually Cost More

Running short of packaging often results in urgent orders.

Emergency deliveries may involve:

• Express production (we now offer a 1 day service)

• Operational disruption

• Increased administration

Planning packaging requirements in advance can help avoid these unnecessary costs.

6. Ordering in Bulk Can Improve Business Efficiency

Larger orders don't just reduce unit costs.

They can also improve:

• Production planning

• Purchasing efficiency

• Stock availability

• Packing operations

• Budget forecasting

Businesses with consistent packaging requirements often benefit from ordering further ahead.

What About Storage Space?

One reason businesses avoid larger orders is warehouse capacity.

Holding excessive packaging stock isn't always practical.

However, this doesn't necessarily mean ordering little and often is the only option.

By reviewing your packaging usage and forecasting future demand, many businesses can find an order quantity that balances storage requirements with improved purchasing efficiency.

The Total Cost of Packaging

When comparing packaging suppliers, many buyers focus solely on the unit price.

In reality, the total cost includes:

• Box price

• Delivery costs

• Administration

• Goods-in handling

• Invoice processing

• Warehouse time

• Emergency orders

• Production setup costs

Looking at the complete picture often reveals opportunities to reduce overall packaging expenditure.

How ASC Direct Can Help

At ASC Direct, we work with businesses of all sizes to help them find the most cost-effective packaging solution.

Whether you're ordering plain or printed corrugated boxes, our team can advise on order quantities that balance unit cost, storage space and operational efficiency.

Many customers find that increasing order quantities can reduce both the cost per box and the number of deliveries they receive throughout the year.

Our aim isn't simply to manufacture boxes—it's to help customers reduce the total cost of their packaging operation.

Quick Purchasing Checklist

Before placing your next packaging order, ask yourself:

✓ How many deliveries do we receive each year?

✓ How much time is spent processing packaging orders?

✓ Could ordering larger quantities reduce our cost per box?

✓ Are emergency packaging orders increasing our costs?

✓ Are we considering the total cost of purchasing, not just the unit price?

Answering these questions could identify opportunities to reduce both packaging costs and administration.

Frequently Asked Questions

Is it cheaper to order packaging in bulk?

In many cases, yes. Larger orders often reduce the cost per box by spreading production setup costs across more units while also reducing delivery and administration costs.

Why do small packaging orders cost more?

Smaller orders can generate additional transport, administration and production setup costs, increasing the total cost of ownership.

How can I reduce packaging costs?

Review your ordering frequency, packaging usage and annual demand. Ordering larger quantities where practical can often reduce overall costs.

Is buying packaging in bulk always the best option?

Not necessarily. The ideal order size depends on storage capacity, cash flow and packaging usage. The goal is to find the right balance between operational efficiency and stock holding.

Can ASC Direct help us choose the right order quantity?

Yes. Our team can advise on order quantities based on your packaging requirements, helping you balance storage, cost and supply. Give us a call on 0800 0731 126 or email sales@asc-cartons.co.uk

James Palfrey-Smith is the General 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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