When Should You Switch From Stock Packaging to Custom Packaging?
Stock packaging is often a great solution when launching a product.
It’s readily available, requires no tooling investment, and works well for lower volumes.
But as production grows, stock packaging may no longer be the most efficient or cost-effective option.
Here are 6 signs it may be time to switch to custom thermoformed packaging.
Your Production Volumes Are Increasing
As volumes increase, custom packaging becomes more attractive.
While custom thermoforming requires an initial investment in development and tooling, those costs are spread across your production volume.
At higher quantities, an optimized custom package can potentially provide a lower cost per unit than an off-the-shelf solution.
Your Packaging Is Larger Than It Needs to Be
Stock packaging wasn’t designed specifically for your product.
That can mean paying for unnecessary material and empty space.
Custom packaging is designed around your product’s dimensions, which can help:
✔ Reduce material usage
✔ Reduce package size and weight
✔ Improve product fit
✔ Reduce shipping and storage space
Even small improvements can generate significant savings at higher volumes.
You’re Adding Extra Components
Are you using foam, cardboard inserts, dividers or tape just to make your stock packaging work?
Those extra components add material, labour and assembly costs.
A custom thermoformed package can incorporate cavities, snaps and other features directly into the design to securely hold your product.
Your Product Isn’t Properly Protected
If your product moves around inside the package, it may be more vulnerable to damage during handling and transportation.
Custom thermoformed trays can be designed to hold products securely in place.
This is especially useful for:
✔ Medical devices
✔ Industrial components
✔ Electronics
✔ Fragile products
✔ Multi-component kits
Better fit can mean better protection without necessarily requiring more material.
Packaging Is Slowing Down Production
The price of the package isn’t your only cost.
If employees spend extra time adding inserts, positioning products or assembling multiple packaging components, labour costs can quickly add up.
Custom packaging can simplify the process by creating a package designed specifically around your product and assembly requirements.
Fewer steps = faster packaging and lower labour costs.
Your Total Packaging Cost Keeps Increasing
When comparing stock and custom packaging, don’t look at the unit price alone.
Consider your complete packaging cost:
Packaging + inserts + labour + storage + transportation + damaged products
A smaller, lighter and more efficient custom package may reduce costs throughout your supply chain.
When Does Custom Packaging Make Sense?
There isn’t one specific volume where custom packaging automatically becomes the better choice.
It depends on your annual quantities, package dimensions, material requirements, labour and current packaging costs.
At CP Formplast, we can review your existing packaging and identify opportunities to improve:
✔ Product fit
✔ Material usage
✔ Package dimensions
✔ Production efficiency
✔ Product protection
✔ Overall cost
With in-house design, prototyping, tooling and 27 thermoforming production lines, we can take your project from concept to full-scale production under one roof.
Is Your Stock Packaging Still the Best Option?
Send us your current packaging, product dimensions and annual quantities, and our team can evaluate whether switching to a custom thermoformed solution makes sense.
Contact CP Formplast today to discuss your packaging project.
