PPWR void-space checklist: optimise shipping boxes in 6 steps
The PPWR's 40% void-space limit can be met reliably with a structured approach. The key is to match box sizes to the real product range rather than working with a few universal boxes.
This checklist takes you through six steps from stock-take to documented calculation. Start by analysing your most-shipped products — that is where the biggest lever is.
Your checklist
- 1Capture your most-shipped products: list the top items and typical baskets with their dimensions.
- 2Check current box sizes: calculate the void-space ratio for each combination and flag the critical cases above 40%.
- 3Adjust the box range: introduce additional, smaller box sizes or use height-adjustable/foldable boxes.
- 4Use filling material in a targeted way: ensure protection without needlessly filling volume — void space counts despite filling.
- 5Embed packing rules in fulfilment: define pick-and-pack rules so the right box size is chosen.
- 6Document the result: file the void-space calculation per standard box as an audit PDF — as evidence of packaging minimisation.
Matching tool
Stay within the PPWR's 40% void-space limit.
PPWR Void-Space Calculator → Check now for freeFrequently asked questions
How do I calculate the void-space ratio?
Void space (%) = (1 − product volume ÷ box volume) × 100. Each cuboid volume is length × width × height; for multiple items the individual volumes are added. The PPWR void-space calculator does this automatically.
Does filling material count as used volume?
What matters is packaging minimisation: the goal is to choose a box that leaves as little empty space as possible. Over-filling with padding does not replace the right box size — it causes additional cost and waste.
Do I need several box sizes?
Usually yes. A tiered box range is the most effective lever to stay within the 40% limit across your whole range. Height-adjustable or foldable boxes reduce the number of sizes needed.