In a context where food packaging costs are skyrocketing, SMEs and agri-food manufacturers are seeking to reconcile agility, controlled budget, and sustainability. However, packaging often remains a poorly controlled expense, even though it impacts logistics, marketing, and cash flow. In this article, discover how small batch orders can become a powerful lever for reducing packaging costs, while enhancing your market flexibility.
I. The Hidden Costs of Mass Packaging
The trap of overstocking: immobilised money, obsolete packaging
Ordering in large quantities may seem cost-effective (lower unit price), but it often hides indirect costs:
- Obsolescence of packaging in the event of product modification or regulatory change.
- Costly and bulky storage.
- Capital tied up in unsold volumes.
High MOQs: a barrier to product innovation
Many traditional printers impose high minimum order quantities (MOQ), which can hinder business innovation. These constraints prove particularly problematic for brands that launch seasonal products or test new offerings (flavours, formats, limited editions).
II. Small packaging series: an agile and economical solution
Adjust volumes to actual sales flow
Working in just-in-time packaging allows the printed volumes to be aligned with actual sales.
This approach is ideal in several scenarios:
- Brands in growth or in market testing phase.
- International brands that adapt legal notices locally.
- Companies with multiple revenue streams and irregular volumes (snacks, dietary supplements, coffees, granolas).
Case Study: LeBepur Optimises Its Packaging Strategy
The challenge: This brand of organic plant powders distributed in Europe ordered twice a year, by reference (matcha, barley, peanut), generating numerous losses.
The solution: Transition to a monthly model for customised packaging orders (minimum €2,000 excluding VAT) in digital printing.
The results:
- Dormant stocks removed
- More flexibility on volumes by references
- Secured margins
An agile method inspired by lean management
Cost reduction in packaging involves an iterative approach: start with small quantities, observe performance in-store or online, adjust volumes according to actual sales, then restart production if necessary. This logic avoids committing to several months of packaging without clear visibility on demand.
This model is particularly suitable for agri-food startups, brands facing strong seasonality, and limited edition products requiring agility and customisation.
III. Succeeding in Your Low-Volume Packaging Strategy: Best Practices
Plan your order cycles intelligently
Adopting small series does not mean disorganising production. The key lies in splitting quantities according to your sales cycles, synchronising orders with logistics flows, and using a tracking table for active and dormant references.
Choosing a digital packaging printer
Unlike heliogravure, digital packaging printing allows for changing visuals without plate costs, launching marketing campaigns more quickly, and achieving a premium finish even with a limited packaging budget.