Packaging waste may not be as visible as lumber stacks or piping reels, but for many distributors, it’s one of the most persistent—and solvable—sources of environmental impact. From shrink wrap and cardboard to unused pallets and foam, excess packaging creates cost, clutter, and waste.
In this case study, we explore how a mid-size building materials distributor successfully adopted a range of strategies to reduce packaging waste across multiple locations—cutting costs, pleasing contractors, and supporting their ESG commitments.
🏢 Company Snapshot
Name: RidgeSupply Co. (fictional)
Locations: 6 regional yards + 2 central warehouses
Focus: General construction materials, roofing, drywall, specialty fasteners
Challenge: High volumes of single-use packaging, excess pallet stock, and frequent landfill runs
🚨 The Problem
Each outbound delivery was wrapped in layers of plastic film
Vendors sent materials with redundant packaging
Pallets piled up with no reuse system
Warehouse bins were overflowing with cardboard waste
ESG clients began requesting waste reports—and Ridge had none
🔄 The Shift: Packaging Waste Reduction Program
🧰 1. Vendor Packaging Agreements
Ridge worked with its top 10 vendors to:
Use returnable packaging where possible
Eliminate double boxing for durable items
Add “minimal packaging” as a PO requirement in their ERP
🏷️ 2. Labeling and Consolidation
ERP upgrades allowed:
Bundling multiple SKUs into shared boxes for repeat contractors
Auto-printing minimal shipping labels and digital invoices
Reduced label waste by 60%
📦 3. Pallet Return and Reuse
They launched a pallet return program, offering credit to contractors who returned pallets. Returned pallets were:
Sorted by condition
Repaired or reused internally
Tracked via barcode in their ERP
🧃 4. Reusable Bins and Totes
For local jobsite deliveries, they tested durable totes for hardware and sealants—tracked through delivery return logs.
📊 The Results (12 Months Later)
42% reduction in shrink wrap use
60% drop in landfill pickups from warehouse sites
15% savings on packaging material costs
2,800 pallets reused through contractor return program
Fewer delivery errors thanks to simplified, consolidated packing
“We realized we were paying for packaging twice—once when we bought it, and again when we threw it away.”
— Logistics Manager, RidgeSupply
🧠 Key Takeaways
Waste reduction starts upstream—with vendor and ERP alignment
Incentivized return programs work when simple and valuable
Even small changes (like fewer labels or better box selection) scale up fast
Tracking is key—ERP tools made progress visible and measurable
Final Thoughts
Packaging waste may seem like a minor issue—but RidgeSupply’s case shows it’s a high-impact area where smart planning, better tools, and aligned partnerships deliver measurable wins. If you’re looking to hit sustainability goals and save money in the process, this is the place to start.
