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Managing packaging inventory isn’t exactly the most glamorous part of running a small business but it is one of those things that quietly makes or breaks your daily operations.
Whether you’re shipping handmade products or running a growing e-commerce store, how you handle your packaging materials like custom printed boxes or custom paper packaging boxes can affect everything from costs to customer satisfaction.
And yet, many small businesses treat it like an afterthought. They buy too much, store it badly, or worse, run out right when orders spike. Sound familiar?
Let’s talk about how to manage your packaging inventory without making it feel like a second full-time job.
Start with What You Actually Use
It seems obvious, but you’d be surprised as many small business owners just estimate their packaging needs based on gut feeling.
Take a week or two and track every single item you use: boxes, tapes, fillers, labels, even stickers if they’re part of your branding.
You don’t need a fancy system at this point. A simple spreadsheet or even a notebook will do. Break your packaging materials into categories. For example:
| Category | Examples |
| Outer Packaging | Custom printed boxes, mailers |
| Inner Protection | Tissue paper, bubble wrap, kraft paper |
| Branding Inserts | Cards, thank-you notes, stickers |
| Sealing Materials | Tape, glue dots |
| Labels | Shipping and return labels |
This clarity helps you identify what’s essential and what’s just taking up shelf space.
Look at your sales data. Do you sell more in November? Do you have slow periods in spring? These patterns should guide how much packaging you stock up on and when.
If you usually sell 500 items a month, don’t order enough materials for 800 just because there was one busy December. But at the same time, don’t assume it’ll always stay slow. Leave room for growth but keep it reasonable.
Maybe order in 2–3-month batches if your storage space allows it. That way, you’re not constantly reordering, but also not sitting on six months’ worth of boxes either.
Some people call this a “reorder point.” It’s the bare minimum you should have on hand to keep things running smoothly.
Let’s say you go through 100 custom paper packaging boxes per week. If shipping takes a week, then your reorder point should probably be around 150 to give yourself some wiggle room. A little buffer goes a long way, especially during busy seasons or supplier delays.
This one trips up a lot of small businesses especially if you’re working from home or a shared space.
Custom printed boxes can be bulky, even if they’re lightweight. Try vertical storage racks or labeled plastic bins to keep things organised. Stack by size, not type, to reduce wasted space. And please, label everything.
Honestly, having a labeled shelf for just packaging inventory might feel like overkill until the day you’re rushing to fulfill orders and can’t find your small mailers.
You don’t want to chase down your supplier every time you’re running low. Find one who can meet your needs consistently especially if you’re using customised packaging. Delays on those can be brutal.
Ask about turnaround times, bulk discounts, and if they offer storage or dropshipping options for your packaging materials. Some even help track your usage and suggest reorder dates, which can take a load off your plate.
You don’t need a full warehouse management system, but even a basic inventory tool like Sortly, Zoho, or even Airtable can help you track what you have, what’s running low, and when you last ordered.
It sounds like one more thing to manage, but honestly, once it’s set up, it saves you from panicking when you’re halfway through packing and realise you’re out of tape. Again.
Things change. You might stop using certain materials or shift to different custom paper packaging boxes as your branding evolves.
Every few months, spend 30 minutes reviewing what you’re still using, what’s gathering dust, and what needs reordering. It’s a small effort that saves you from bigger headaches later.
This is a weird one, but important. Not everything will go as planned. Maybe your supplier goes out of stock. Maybe you test new packaging that changes how much space you need. Try not to lock yourself into overly rigid systems. Give yourself permission to adapt.
Final Words!
Efficient packaging inventory management helps small businesses reduce waste, control costs, and ensure smooth daily operations.
By tracking stock levels, setting reorder points, and using the right tools, companies can stay organised and meet customer demands without delays.
Staying consistent with these practices not only improves workflow but also supports long-term growth and stability. Make inventory control a priority to keep your packaging process efficient and cost-effective.
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