{"id":22799,"date":"2026-09-15T08:00:56","date_gmt":"2026-09-15T08:00:56","guid":{"rendered":"https:\/\/www.teamplast-srl.it\/?p=22799"},"modified":"2026-09-16T09:11:27","modified_gmt":"2026-09-16T09:11:27","slug":"packaging-sovradimensionato-riduzione","status":"publish","type":"post","link":"https:\/\/www.teamplast-srl.it\/en\/packaging-sovradimensionato-riduzione\/","title":{"rendered":"Oversized packaging: reducing material without sacrificing performance | Teamplast"},"content":{"rendered":"<article>\n<h2>Oversized packaging: how much material do we waste without realizing it?<\/h2>\n<p>In flexible packaging, a few grams seem irrelevant. Multiplied by hundreds of thousands or millions of pieces, however, they become <strong>tons of raw material, purchasing costs, transformation energy, weight moved and waste to be managed at end of life<\/strong>.<\/p>\n<p>For this reason the <strong>oversized packaging<\/strong> It deserves attention: packaging must protect the product and function in the customer&#039;s process, but material beyond the necessary level does not automatically create value.<\/p>\n<h2>What is oversized packaging?<\/h2>\n<p>It is a packaging that, in relation to the required function, uses <strong>more material, weight, or volume than necessary<\/strong>.<\/p>\n<p>In flexible film it can derive from:<\/p>\n<ul>\n<li>a thickness historically maintained \u201cfor safety\u201d;<\/li>\n<li>specifications never reviewed;<\/li>\n<li>excessive margins on dimensions;<\/li>\n<li>a project no longer aligned with the materials and processes available today.<\/li>\n<\/ul>\n<p>Warning: Calling it oversized requires proof.<\/p>\n<p>Thicker film may be essential to withstand punctures, loads, temperatures, packaging speeds, or critical seals.<\/p>\n<p><strong>Optimization isn&#039;t something you decide on just by looking at microns.<\/strong><\/p>\n<h2>The hidden cost of a few grams<\/h2>\n<p>Let&#039;s take a reference from <strong>25 g<\/strong> produced in <strong>2 million pieces per year<\/strong>: I am <strong>50,000 kg of material<\/strong>.<\/p>\n<p>If testing and validation allowed us to get down to <strong>22.5 g<\/strong>, a reduction of the <strong>10%<\/strong>, consumption would become <strong>45,000 kg<\/strong>.<\/p>\n<p>The theoretical saving would therefore be <strong>5,000 kg per year<\/strong>.<\/p>\n<p>The economic benefit isn&#039;t just the cost of the raw material. Less weight can also mean less material to handle and store and, in some cases, improved logistics efficiency.<\/p>\n<p>The environmental advantage arises above all from the material that does not need to be produced and transformed.<\/p>\n<\/article>\n<article>\n<h2><img loading=\"lazy\" decoding=\"async\" class=\"alignnone  wp-image-22800\" src=\"https:\/\/www.teamplast-srl.it\/wp-content\/uploads\/2026\/08\/infografica-packaging-sovradimentionato-e1787577642247-300x201.png\" alt=\"infografica packaging sovradimentionato\" width=\"708\" height=\"474\" srcset=\"https:\/\/www.teamplast-srl.it\/wp-content\/uploads\/2026\/08\/infografica-packaging-sovradimentionato-e1787577642247-300x201.png 300w, https:\/\/www.teamplast-srl.it\/wp-content\/uploads\/2026\/08\/infografica-packaging-sovradimentionato-e1787577642247-1024x687.png 1024w, https:\/\/www.teamplast-srl.it\/wp-content\/uploads\/2026\/08\/infografica-packaging-sovradimentionato-e1787577642247-768x515.png 768w, https:\/\/www.teamplast-srl.it\/wp-content\/uploads\/2026\/08\/infografica-packaging-sovradimentionato-e1787577642247-18x12.png 18w, https:\/\/www.teamplast-srl.it\/wp-content\/uploads\/2026\/08\/infografica-packaging-sovradimentionato-e1787577642247-600x403.png 600w, https:\/\/www.teamplast-srl.it\/wp-content\/uploads\/2026\/08\/infografica-packaging-sovradimentionato-e1787577642247-900x604.png 900w, https:\/\/www.teamplast-srl.it\/wp-content\/uploads\/2026\/08\/infografica-packaging-sovradimentionato-e1787577642247-400x269.png 400w, https:\/\/www.teamplast-srl.it\/wp-content\/uploads\/2026\/08\/infografica-packaging-sovradimentionato-e1787577642247.png 1420w\" sizes=\"auto, (max-width: 708px) 100vw, 708px\" \/><\/h2>\n<h2>Downgauging: design, not just reduction<\/h2>\n<p>The <strong>downgauging<\/strong> effective starts from the function.<\/p>\n<p>The performance requirements are identified, the causes of any failures are analyzed, the formulation and geometry are studied, samples are produced and verified on the real process.<\/p>\n<p>An unvalidated reduction can shift the cost elsewhere:<\/p>\n<ul>\n<li>more packaging waste;<\/li>\n<li>breakages during transport;<\/li>\n<li>product loss.<\/li>\n<\/ul>\n<p>These problems can quickly cancel out the benefit gained on packaging.<\/p>\n<h2>The connection with the PPWR<\/h2>\n<p>The <a href=\"https:\/\/eur-lex.europa.eu\/eli\/reg\/2025\/40\/oj?locale=it\" target=\"_blank\" rel=\"noopener\"><strong>Regulation (EU) 2025\/40<\/strong><\/a> makes minimization a structural principle of design.<\/p>\n<p>Annex IV sets out performance criteria to be considered, including:<\/p>\n<ul>\n<li>product protection;<\/li>\n<li>production and filling processes;<\/li>\n<li>logistics;<\/li>\n<li>functionality;<\/li>\n<li>hygiene;<\/li>\n<li>safety.<\/li>\n<\/ul>\n<p>This approach is interesting because it overcomes two extremes:<\/p>\n<p><strong>\u201cLet&#039;s add a few more microns to be on the safe side\u201d <\/strong>And <strong>\u201cWe reduce at all costs.\u201d.<\/strong><\/p>\n<p>The correct way is to document the level of material required for the function.<\/p>\n<h2>A practical method of revision<\/h2>\n<ul>\n<li>Measure the actual weight and thickness of the current reference, not just the nominal ones.<\/li>\n<li>Collect data on breakages, scraps, and problems on the line.<\/li>\n<li>Define which performances are truly critical.<\/li>\n<li>Evaluate material, formulation, dimensions and welds.<\/li>\n<li>Produce an optimized variant and test it under real-world conditions.<\/li>\n<li>Quantify annual savings only after validation.<\/li>\n<\/ul>\n<h2>The Teamplast approach<\/h2>\n<p>Withholding tax reduction is one of the cases in which <strong>sustainability and economy can go in the same direction<\/strong>.<\/p>\n<p>But it only works if it is supported by technology.<\/p>\n<p>The goal isn&#039;t to sell a thinner envelope: it&#039;s to design an envelope that performs the same function using fewer resources when that&#039;s actually possible.<\/p>\n<p><a href=\"https:\/\/www.teamplast-srl.it\/en\/contatti\/\"><strong>Give us a reference:<\/strong><\/a> We can discuss weight, performance, and optimization options together, evaluating where material can be reduced without compromising functionality, safety, and process continuity.<\/p>\n<\/article>","protected":false},"excerpt":{"rendered":"<p>Packaging sovradimensionato: quanto materiale utilizziamo inutilmente senza accorgercene? Nel packaging flessibile pochi grammi sembrano irrilevanti. Moltiplicati per centinaia di migliaia o milioni di pezzi, per\u00f2, diventano tonnellate di materia prima,&#8230;<\/p>","protected":false},"author":2,"featured_media":22801,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[1],"tags":[],"class_list":["post-22799","post","type-post","status-publish","format-standard","has-post-thumbnail","category-news"],"_links":{"self":[{"href":"https:\/\/www.teamplast-srl.it\/en\/wp-json\/wp\/v2\/posts\/22799","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.teamplast-srl.it\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.teamplast-srl.it\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.teamplast-srl.it\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.teamplast-srl.it\/en\/wp-json\/wp\/v2\/comments?post=22799"}],"version-history":[{"count":1,"href":"https:\/\/www.teamplast-srl.it\/en\/wp-json\/wp\/v2\/posts\/22799\/revisions"}],"predecessor-version":[{"id":22802,"href":"https:\/\/www.teamplast-srl.it\/en\/wp-json\/wp\/v2\/posts\/22799\/revisions\/22802"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.teamplast-srl.it\/en\/wp-json\/wp\/v2\/media\/22801"}],"wp:attachment":[{"href":"https:\/\/www.teamplast-srl.it\/en\/wp-json\/wp\/v2\/media?parent=22799"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.teamplast-srl.it\/en\/wp-json\/wp\/v2\/categories?post=22799"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.teamplast-srl.it\/en\/wp-json\/wp\/v2\/tags?post=22799"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}