Guide / Stage guides / Chapter 9.5
Planning packaging supply at scale.
At volume, running out of packaging can stop dispatch. Here's how to plan your packaging supply around usage, lead times and peak seasons, so the right boxes are always on hand.
The short answer
Planning packaging supply comes down to four things: a clear specification for every item, knowing your usage, knowing your lead times and setting reorder points with a buffer for peaks. Standard lead times are 5–10 business days for digital printing and 10–15 business days for screen, flexo and offset, counted from artwork approval. Custom rigid boxes take 15–20 working days express or 6–8 weeks standard, custom collapsible magnetic boxes 4–6 weeks, and foil 3–4 weeks express or 6–8 weeks standard. Stocked items dispatch in 1–3 business days, subject to availability. Peak periods take longer. Reorder early enough to cover the lead time, delivery and a safety margin.
The four parts of a supply plan
1. Specify every item
Record the box style, size, board, print method, colours and artwork version for every packaging item. A specification keeps every order consistent within agreed tolerances, and means anyone in your team can reorder it. Our quote request is the easiest way to send us the details.
2. Know your usage
Track how many of each item you use per week or month, and how that changes through the year. Usage, not guesswork, should drive your orders.
3. Know your lead times
Lead times depend on the product and print method, including rigid, magnetic, foil and made-to-order plain boxes, which each have their own timing. Add delivery time to your location, plus time for artwork changes and proof approval if anything is new. Check our current lead times before peak periods.
4. Set reorder points
A reorder point is the stock level that triggers a new order. It should cover your usage during the lead time, plus a buffer.
Working out a reorder point
An example with round numbers. Use your own usage and lead times.
| Step | Example |
|---|---|
| Weekly usage | 500 boxes a week |
| Lead time including delivery | 3 weeks |
| Usage during the lead time | 500 × 3 = 1,500 boxes |
| Safety buffer | 1 extra week = 500 boxes |
| Reorder point | Reorder when stock falls to 2,000 boxes |
Planning for peaks
Peak seasons such as the lead-up to Christmas and major sales events increase usage sharply and can stretch lead times. Look at last year's usage, plan your peak orders early and get any new artwork approved well before you need it.
- Confirm peak quantities and timing early, so production can be planned.
- Avoid artwork changes close to a peak. Use proven, approved files.
- Keep a buffer of your most-used items going into peak.
Where we fit in
We supply stock and custom packaging. Our team quotes, usually replying within 1 business day, and can supply plain samples. Before every new print, we email a digital proof, typically within 1 business day of receiving your artwork. Planning, storage and reorder timing sit with your business, so build our confirmed lead times into your own plan and order with enough notice for each run.
What it means for you
The same question, answered for where your business is today.
Choose your stage at the top of the page to open the advice for you.
Start-up · under 100 units
Supply planning at this stage is simple: keep a few weeks of packaging on hand and reorder stock items before you run low.
Set a reminder to check stock every week.
Growing · 100 to 2,499 units
Start tracking monthly usage for each item and set a simple reorder point for your custom packaging, based on its lead time.
Try this: put the reorder point on a label on the shelf, so anyone can see when to reorder.
Enterprise · 2,500 units and more
Run packaging like any other critical supply: specifications, usage forecasts, reorder points with buffers, and peak plans agreed well in advance.
Review usage and reorder points every quarter, and before every peak.
Common mistakes
- 1Reordering when you've run out. By then, the lead time means a gap in supply. Reorder at your reorder point.
- 2Forgetting delivery and proof time. Lead times start from artwork approval. Add delivery and approval time to your plan.
- 3Changing artwork before a peak. New artwork needs a new proof. Make changes well before busy periods.
- 4No buffer. Usage spikes. A small safety buffer protects dispatch.
Supply planning questions
How far ahead should I order custom packaging?
What is a reorder point?
How do I plan for Christmas?
Do you hold stock for customers?
How do I keep every order consistent?
Keep reading
Packaging at scale
Planning a large run?
Send us your specifications, quantities and timing. Our Melbourne team will come back with options and confirmed lead times, usually within 1 business day.