Overpackaging is excessive or unnecessary packaging. It is defined by the Institute of Packaging Professionals as "a condition where the methods and materials used to package an item exceed the requirements for adequate containment, protection, transport, and sale".[1]
Reducing overpackaging is a key strategy in source reduction, which aims to minimize waste before it is generated.[2] It aligns with the waste hierarchy principle of reduce, reuse, recycle, where eliminating unnecessary packaging takes precedence over recycling or disposal.[3] Overpackaging occurs in various sectors, including e-commerce and retail food packaging. Some cases are clearly excessive, while others depend on subjective judgment. [4]
For example, luxury packaging frequently uses more packaging than the minimum requirements. Brand managers believe that premium packaging is needed to communicate the extra value the contents.[5] Gift wrapping traditionally involves additional layers, though consumer preferences and cultural practices sustain its use.[6]Decorative boxes are an art form which clearly exceed minimum functional requirements.[7]
Excess packaging by design
Carton of breakfast cereal: designed intentionally with an inefficient shape, adding to packaging waste
Breakfast cereal boxes (along with other similar products) serve as a typical case of excessive packaging, commonly featuring a dual-layer structure comprising a cardboard folding box with an inner plastic bag.
The amount of paperboard in a folding carton blank is the sum of the area of all faces of the carton plus the area of the inner flaps, plus a glued lap. This area can be compared to the volume of the carton by a ratio for a measure of efficiency. Depending on the specific design and choice of length, width, and height, this efficiency can vary significantly.[8]
Typical commercial designs prioritize height and width over thickness, resulting in poor material-to-volume ratios despite packaging designers recognizing potential reductions in cardboard usage through optimized sizing. However, marketing considerations often prevail, favoring oversized "billboard-style" packages that sacrifice material efficiency for enhanced graphic display space. More sustainable alternatives like single-layer resealable plastic bags further reduce material consumption but introduce plastic waste challenges, underscoring the need for innovative sustainable materials in packaging design.[9][10]
Underfilled packages
The 300 aspirin tablets take up less than a quarter of the container they came in. Using an appropriately-sized container would minimise packaging waste.
Underfilled packaging (Slack-fill packaging) refers to the design of packaging containers with internal volumes significantly exceeding the actual space required for the product, resulting in non-functional empty areas.[11] The U.S. Food and Drug Administration (FDA) has defined six permissible reasons for functional underfilling in packaging: additional space required to protect contents; extra space necessitated by machinery requirements related to the packaged product; additional space resulting from natural settling of products during transportation; packaging-related space needed to facilitate food preparation or consumption; reusable containers with extra space (which helps display contents and maintains significant value after product use - including food containers, promotional items, commemorative durable containers, and gift sets); and additional space resulting from the inability to increase fill quantity or reduce package size due to food labeling requirements, tamper-evident features, or efforts to facilitate handling or prevent theft. The FDA considers packaging to be misleading if manufacturers fail to adequately fill packages for reasons other than those specified above.[11][12]
E-commerce
Delivery of a small item in a much larger corrugated box, requiring air pillows for void-fill. A simple padded mailer would have been adequate.
In E-commerce, “the overpackaging of products has become a major ecological concern.”[13][14] While traditional retail packaging often emphasizes product display functionality and may adopt minimalist designs, e-commerce logistics systems require independent shipping handling. This process involves multiple packaging layers: first, the retail packaging itself must be transported through courier systems; second, these retail packages are frequently placed in oversized corrugated boxes with substantial filler materials for stabilization.[15]
This packaging system presents a dual paradox: if manufacturers optimize packaging design for e-commerce shipping needs, it may result in excessive packaging for physical retail; conversely, packaging designed solely for retail display often fails to meet e-commerce logistics protection requirements.[16]
Taking consumer electronics as an example, packaging engineers must balance product fragility with anticipated shipping stresses, though excessive protection frequently leads to overuse of cushioning materials and improperly enlarged packaging dimensions.
Special logistics requirements exacerbate packaging issues: some products require dual-layer packaging systems (pallet shipping packaging + individual delivery packaging). This design not only reduces production efficiency but also highlights the need for innovative packaging solutions.[17]
Food overwraps
Fresh produce is usually presented for sale without packages, allowing shoppers to touch the items and choose which ones to buy. Some foods are over wrapped with shrink film, individually bagged, or further protected to increase the appeal to some customers. However, the necessity of such additional packaging is frequently subject to debate.[18]
A tomato on a plastic tray and with a plastic shrink film
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