Buying packaging seems straightforward—until timelines slip, quality varies, freight costs spike, or the “same” material behaves differently in production. Here are the issues we see most often and how to prevent them.
1) Hidden Costs That Don’t Show Up in the Quote
- Tooling, plates, dies, and change fees
- Freight, fuel surcharges, and dimensional weight impacts
- Rush fees and expediting
- Overruns/underruns (you may pay for more than you planned)
Fix: Ask for a “fully landed” cost breakdown and confirm assumptions in writing.
2) Inconsistent Quality From Run to Run
- Color shifts between print runs
- Dimensional variation affecting fit
- Weak glue joints or cracking at folds
- Warping from humidity or board variation
Fix: Define quality specs (tolerances, ink targets, board grades) and require golden samples.
3) Long or Unreliable Lead Times
Packaging is often the long pole in a product launch. Material shortages, capacity constraints, and approvals can derail schedules.
Fix: Build in buffer time, confirm production calendars, and establish a reorder trigger (not “when we’re almost out”).
4) Artwork and Dieline Mistakes
- Missing bleeds and safe zones
- Wrong dieline version used
- Barcodes/QR codes placed near folds or coatings
- RGB files sent instead of CMYK/spot builds
Fix: Use a prepress checklist and get a press proof for critical launches.
5) Over-Engineering (Paying for Packaging You Don’t Need)
Many teams default to “stronger is safer,” but that can mean unnecessary cost and waste.
Fix: Align protection to real distribution risk and validate with transit testing and right-sizing.
6) Sustainability Claims That Don’t Hold Up
- Materials labeled “recyclable” that aren’t accepted locally
- Mixed-material designs that reduce recyclability
- Greenwashing risk from vague certifications
Fix: Confirm end-of-life pathway, request documentation (FSC, PCR %, etc.), and design for mono-material where possible.
7) Supplier Misalignment
A supplier might be great at one format (corrugated) and weak at another (rigid, medical packaging, precision inserts).
Fix: Choose suppliers based on proven capability, not just price.
Want to Avoid These Problems?
Influence Packaging helps brands source reliably, define specs, validate prototypes, and prevent costly surprises before production.