Case Study: EPS-Free Retail Packaging for Homegoods with 36% Less Volume

The Challenge

A growing homegoods brand was preparing for national retail rollout but faced mounting concerns over its existing retail packaging. The current solution relied heavily on EPS foam, which added unnecessary weight, increased shipping volume, and conflicted with the sustainability goals of both the brand and its retail partners.

The packaging also failed to optimize retail shelf space, as the bulky design limited unit count per pallet and contributed to higher freight costs. With increasing pressure from retailers to eliminate EPS and reduce environmental impact, the brand needed an immediate solution that could reduce volume and improve sustainability – without compromising product protection.

The EPS-Free Retail Packaging Solution

GreenDot Packaging engineered a fully corrugated retail packaging solution tailored specifically for this homegoods item. The structural packaging team began by benchmarking the original design’s material usage and footprint. The EPS insert and outer dimensions were carefully analyzed to identify space and weight inefficiencies.

The optimized retail packaging design replaced the EPS with a die-cut corrugated insert that protected the product while lowering both volume and material usage. Our team achieved:

• A 23% reduction in material weight
• A 36% total packaging volume reduction
• A switch to 100% recyclable corrugate
• Retail shelf optimization for increased unit count per pallet

These improvements not only aligned with retailer sustainability requirements but also improved shipping density and reduced overall packaging costs for the brand.

The Results

• EPS foam eliminated entirely
• Material usage reduced from 0.94 m² to 0.72 m²
• Package volume reduced from 0.0142 m³ to 0.009 m³
• Retail packaging for homegoods now meets eco-friendly retailer mandates
• Freight efficiency improved due to smaller footprint

Key Takeaways

Retail packaging for homegoods must evolve to meet retailer expectations for sustainability, space efficiency, and recyclability. By replacing EPS foam with a smart, corrugated-only solution, brands can reduce material costs and environmental impact while improving shelf presence and logistics.

Need Smarter Retail Packaging for Homegoods?

From concept to testing and full production, GreenDot Packaging specializes in retail packaging for homegoods that meets performance and sustainability goals. Contact us to get started.