Components and material use
Count trays, inserts, sleeves, cartons, labels, closures, void fill, shippers, and repeated functions.
Packaging audit services
Find hidden costs inside the package and the packing process.
A practical current-state review can begin with photographs, a rough volume estimate, and the business pressure you are trying to solve. Complete specifications are not required for an initial conversation.
Current-state packaging reviewStart with what you know.
ProductPhoto, link, or sample
VolumeRough annual units or timing
PackageVisible materials and components
PressureCost, labor, damage, freight, or launch
StructureSourcingPackout laborDamageFreight + storageSustainability
Current-state mapWhat appears to be happening now
Evidence gapsWhat needs observation, quotation, or testing
Priority opportunitiesWhere savings or simplification may be worth pursuing
Next-step planPractical validation path—not a premature promise
Customer suppliedObservedSupplier quotedEstimatedUnknown
Audit scope
A useful audit follows the cost through the entire packaging system.
The objective is not to overwhelm the customer with a data request. We begin with available information, identify what matters, and separate confirmed facts from assumptions and unknowns.
Packout and handling
Map hand placements, folding, loading, closure, labeling, inspection, replenishment, movement, and rework.
Damage and performance
Review damage modes, returns, replacement product, emergency freight, containment, and testing history.
Freight and storage
Review dimensions, dimensional weight, pallet density, warehouse cube, nesting, inventory, and fulfillment flow.
Labor and throughput
Identify observed or standard time, wage assumptions, burden, annual volume, shifts, throughput, and exceptions.
Supplier conditions
Review specifications, quotations, minimums, lead times, freight, tooling, inventory, and sourcing complexity.
Sustainability evidence
Review material weight, recycled content, recyclability, waste, transport efficiency, and supplier documentation.
Opportunity summary
Prioritize potential savings, risks, data gaps, validation steps, and the most practical path forward.
Expanded current-state review
We audit the system—not only the box.
A review can begin with photographs and approximate volume. As the opportunity develops, we can evaluate the package, materials, packout sequence, equipment, contract labor, sourcing, freight, storage, and evidence behind current assumptions.
Corrugated & folding cartonsChipboard & printed insertsFoam & ESD protectionThermoformed trays & clamshellsFilms, bags & unitizationAutomation opportunitiesContract assembly & co-packingMoving, storage & warehouse materials
You do not need complete specifications to start. RPG can help identify what is known, what is missing, and which facts matter before deeper engineering or quotation begins.
Audit deliverables
Evidence before promises.
A packaging cost-reduction audit should not begin with a predetermined package or manufacturer. The output should clarify what is known, where cost is occurring, what still requires observation or quotation, and which opportunities justify further work.
- Current package and component record
- Current-state packout sequence
- Cost and evidence matrix
- Risk, constraint, and data-gap summary
- Prioritized opportunity list
- Recommended validation path
Start with the current state
Send a few photographs and tell us what is creating pressure.
Approximate annual volume and a short description are enough to begin. We will identify the next useful questions rather than asking for every specification up front.