How Packaging Optimization Saved $11,900 for Just One Product

Overview

Our client—Makaka On The Run—sold camera covers for smartphones. Originally, the product was packaged in a two-sided blister-sealed carton board that added unnecessary bulk, cost, and production time. We stepped in to streamline this.

The Challenge

Reduce overall cost across multiple areas:

FBA Fulfillment Fees
International Shipping
Storage in Fulfillment Centers
Packaging Production Costs

The question: Do we really need to spend more and use oversized, complex packaging if a simpler version gets the job done just as well?

Our Solution

We completely redesigned the packaging:

Switched from heat-sealed double-sided blister carton to a simple 5-cent envelope solution
Reduced packaging volume drastically
Maintained branding and unboxing experience

Results & Savings Breakdown (based on 10,000 units/year)

Cost Category	Before	After	Savings
FBA Fulfillment Fees	€0.15 higher per unit	–	€1,500
International Shipping	$2,800	$300	$2,500
Storage Fees	13 shelf spots = €36.40/month	1 spot = €2.80/month	€400/year
Packaging Production Cost	$0.80/unit	$0.05/unit	$7,500

Total Savings: $11,900/year

Side Benefits

Faster Production Time: Reduced packaging lead time by over a week
Simpler Fulfillment: Easier to pick & pack
Better Eco-Footprint: Less material, less waste

Conclusion

Packaging isn’t just about aesthetics—it’s a hidden profit driver. In this case, we reduced size, cost, and complexity while unlocking nearly $12,000 in annual savings—with zero compromise in customer satisfaction.

Want to explore how much your brand could save?

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If you’re ready to take the next step in optimizing your sourcing and boosting your profitability, we’d love to help. Contact us today for a free consultation to explore how we can work together to create a customized sourcing strategy tailored to your business.