Reduce packaging costs: How companies can cleverly reuse cardboard waste
by Anna Ullmann on Jun 10, 2026Packaging is part of everyday business for many companies. Whether it's spare parts, office supplies, online shop orders, or industrial products: goods are packaged, shipped, and protected every day.
Many companies still consider packaging a mere side issue. However, a look at current figures shows how significant this topic has become.
In short
Used cardboard boxes can be processed directly into packaging padding with a cardboard perforator. Companies thus save on filling material, disposal costs, and create a more sustainable shipping process, sometimes saving 200 to 300 euros per month.
Current Packaging Figures from Europe
According to Eurostat, approximately 79.7 million tons of packaging waste were generated in the European Union in 2023. Paper and cardboard accounted for the largest share, with 32.3 million tons, which corresponds to 40.4 percent of total packaging waste.
For companies, this raises a simple question: Why dispose of cardboard boxes if they can be reused as packaging material?
Why Packaging is Becoming Increasingly Important for Businesses
Packaging not only incurs purchase costs. It affects storage space, shipping processes, disposal, sustainability goals, and customer perception.
Companies with regular shipping, in particular, are feeling the rising costs of cardboard boxes, filling material, and packaging logistics. At the same time, pressure to use resources more efficiently is growing.
- Purchasing packaging materials: Cardboard boxes, cushioning material, packing paper, and films must be reordered regularly.
- Warehousing: Packaging materials require storage space.
- Disposal: Cardboard boxes from incoming goods must be collected and removed.
- Procurement effort: Prices, delivery times, and stock levels must be monitored.
- Packing time: Employees need suitable materials directly at their workstation.
Practical consideration: Those who dispose of cardboard boxes while simultaneously purchasing filling material often pay twice: once for disposal and once for new packaging material.
The new EU Packaging Regulation increases pressure
With the European Packaging and Packaging Waste Regulation (PPWR), recyclability, material efficiency, and circular economy are increasingly coming into focus.
The regulation entered into force on February 11, 2025, and will generally apply from August 12, 2026. The aim is to reduce packaging waste and better reintegrate packaging into the recycling loop.
For companies, this means that packaging processes should not only be cost-effective but also resource-efficient, transparent, and future-proof.
Source: European Commission: Packaging waste
Cardboard waste becomes packaging material
Almost every company generates cardboard boxes daily: in incoming goods, from supplier packaging, product boxes, or returns.
Many of these boxes end up directly in the waste paper bin. However, they can often be given a second life.
Cardboard perforators like the HSM ProfiPack transform used cardboard boxes into flexible cushioning and filling material. The cardboard is cut, padded, and then directly used to protect new shipments.
Before
- Cardboard boxes are disposed of
- Filling material is purchased
- Dependence on suppliers
- More storage required
After
- Cardboard boxes are reused
- Own cushioning material is produced on-site
- Less purchase of filling material
- More sustainable shipping process
Practical example: 200 to 300 euros less in packaging costs per month
The potential can be seen in the example of the Austrian online retailer myProduct.at.
The company was looking for a more sustainable alternative to conventional filling material and wanted to make better use of existing cardboard boxes.
After introducing an HSM ProfiPack, myProduct.at planned savings of around 200 to 300 euros per month, as significantly less external packaging material would need to be purchased in the future.
Calculation example
With 200 to 300 euros less in packaging costs per month, the annual savings potential amounts to approximately 2,400 to 3,600 euros. Depending on shipping volume, cardboard availability, and previous filling material, the potential in your own company may be higher or lower.
Source: HSM Case Study: myProduct
Other companies report positive results
Other companies have also been able to optimize their packaging processes by reusing cardboard boxes.
According to HSM, cable assembly company WUSTEC ships around 8,000 packages per year. By using a ProfiPack, the company was able to forgo the purchase of filling material. According to the case study, the investment paid for itself in about a year.
Source: HSM Case Study: WUSTEC
Which companies benefit from reusing cardboard boxes?
Reusing cardboard boxes is particularly interesting for companies that regularly receive cardboard boxes and also ship goods.
- Online shops
- Industrial companies
- Wholesalers
- Spare parts dealers
- Shipping departments
- Logistics companies
- Warehouse operations
Quick self-check
Reusing cardboard boxes can be particularly worthwhile if several of these points apply:
- Cardboard boxes are regularly received in incoming goods.
- Filling material is purchased for shipping.
- There are ongoing disposal costs for cardboard boxes.
- Packaging material takes up a lot of storage space.
- Sustainability plays a role for customers or in tenders.
Advantages at a glance
- Lower packaging costs: Existing cardboard boxes are reused.
- Less purchase of filling material: Cushioning material is produced directly in the company.
- Less disposal effort: Cardboard waste gets a second life.
- More sustainable shipping processes: Resources are used more efficiently.
- Reduced plastic consumption: Bubble wrap and other filling materials can be reduced.
- Greater independence: Companies are less dependent on supply bottlenecks for filling material.
View HSM ProfiPack at Wiepa
Do you want to reduce packaging costs and reuse cardboard boxes efficiently? With the HSM ProfiPack, you can transform used cardboard boxes directly on-site into practical cushioning and filling material.
View HSM ProfiPackConclusion: The cheapest raw material is often already in stock
Rising material costs, new legal requirements, and growing sustainability goals are leading companies to re-evaluate their packaging processes.
One of the simplest solutions is often directly on-site: cardboard boxes that were previously disposed of can be given a second life as high-quality packaging material.
Companies thus reduce costs, save resources, and create a more sustainable shipping process.
Anyone who regularly disposes of cardboard boxes while simultaneously purchasing packaging material should examine whether reuse is worthwhile for their own company.
Frequently Asked Questions
How much cardboard is needed for a cardboard perforator to be worthwhile?
Even with regular shipping of a few packages per day, the investment can pay for itself within a few months, as the practical examples show.
Does cardboard cushioning completely replace all other filling materials?
For most standard shipments, yes; for very fragile or heavy goods, additional protection may still be useful.
When does the new PPWR packaging regulation become binding?
The regulation has been in force since February 2025 and will generally apply from August 12, 2026.
Further Wiepa Guides
New EU Packaging Regulation (PPWR): What companies need to know now
Packaging material for online shops and businesses
