Reducing Costs & Waste Through Tray Optimization

Client Overview

A nationally distributed food brand approached Adept to improve the efficiency of its product packaging for retail display. The brand was experiencing rising packaging costs and material waste due to oversized trays that weren’t aligned with updated product dimensions. They needed a smarter, more sustainable packaging solution without sacrificing shelf presence or product protection.

Adept helped the client eliminate unnecessary packaging costs while improving sustainability and shelf impact. The optimized tray design reduced material use, aligned with updated SKUs, and set the foundation for broader packaging efficiency across the portfolio.

The Challenge

As the brand’s product assortment evolved, existing display trays no longer aligned with the actual pack sizes, creating both inefficiencies and waste. The client needed a tray structure that was more cost-effective, visually optimized, and adaptable across multiple items without disrupting the existing supply chain.

  • The project required a redesigned display tray for four SKUs with different dimensions

  • Excess material and inefficient layout were driving up packaging costs

  • Current trays were overbuilt, leading to unnecessary waste and production time

  • The trays needed to support structural integrity and visual appeal for retail shelves

  • The client had limited internal resources to evaluate or execute optimization opportunities

Our Approach

Adept reviewed the full portfolio of affected SKUs and conducted structural analyses to right-size the packaging and optimize material use. We then developed and tested a redesigned tray format that aligned with both functional and marketing goals, ensuring it would fit efficiently on the shelf while using fewer resources.

  • Conducted a review of all primary pack sizes across SKUs

  • Identified areas of material overuse and dimensional misalignment

  • Developed and tested a new tray structure using less board while maintaining strength

  • Aligned packaging dimensions to improve pallet efficiency and minimize void fill

  • Provided structural samples and cost modeling to support implementation

The Impact

Adept's end-to-end optimization delivered more than just higher numbers:

  • 12% reduction of material consumption

  • 15% more cases/pallets, resulting in more available production floor space

  • $45,000 in cost savings resulting from material reduction

  • $7,629 in freight savings due to pallet optimization

This isn't just a fix. It’s a transformation.

Let’s Talk Efficiency Gains

Want to reduce production costs, increase throughput, or optimize your packaging line? Let’s connect.

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