Guide / Ordering & production / Chapter 6.7
Reorders and holding stock.
Running out of packaging stops orders going out. Holding too much ties up cash and space. Here's how to work out how much packaging to keep on hand and when to reorder.
The short answer
Keep enough packaging to cover your usage while a new order is being made and delivered, plus a buffer for busy weeks. That number is your reorder point. When stock falls to it, reorder. Our stocked items dispatch in 1–3 business days, subject to availability, so stock packaging needs only a small buffer. Custom packaging takes 5–10 business days for digital printing and 10–15 business days for screen, flexo and offset (longer in peak periods), so it needs more planning.
Work out your reorder point
1. Know your usage
Count how many of each packaging item you use in a typical week. Use a recent average, not your best or worst week.
2. Know your lead time
Use our lead time for that item plus delivery time. For custom packaging, the lead time runs from artwork approval, so add time for quoting and proof approval too, especially for a new design. Check our current lead times before peak periods.
3. Add a buffer
Add a safety buffer for busy weeks, delays and growth. One to two weeks of usage is a common starting point. Increase it before peak seasons.
4. Do the sum
Reorder point = weekly usage × (lead time in weeks + delivery in weeks + buffer in weeks). When your stock falls to that number, place your next order.
5. Count what's already on order
If you've already placed an order that hasn't arrived, count it. Compare your reorder point with what you have on hand plus what's on order, less anything already committed, so you don't reorder twice.
A worked example
Made-up numbers to show the method. Use your own usage and our lead time for each item.
| Step | Example |
|---|---|
| Weekly usage | 100 printed mailer boxes a week |
| Lead time | Digital printing 5–10 business days, so allow 2 weeks, plus about 1 week for delivery |
| Buffer | 2 weeks for busy periods |
| Reorder point | 100 × (2 + 1 + 2) = 500 boxes |
| What it means | When you're down to about 500 boxes, reorder |
How much to order each time
Your reorder point tells you when to order. How much to order depends on a few things: the cost per unit at different quantities, how much storage space you have, how much cash you want tied up, and how likely your packaging is to change.
Many businesses order enough for a set period, such as two or three months, then adjust as they learn. Keep flat-packed boxes somewhere dry and off the floor, and use the oldest stock first.
Storing packaging well
- Keep it dry. Damp cardboard loses strength and can warp.
- Keep it flat. Store boxes flat and stacked neatly so they don't bend or crush.
- Keep it off the floor. A pallet or shelf protects against spills and damp.
- Keep it labelled. Mark each stack with the size and item code so packers grab the right one.
- Use oldest first. Rotate stock so nothing sits for too long.
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
With stock packaging dispatching in 1–3 business days, you can keep a small supply and reorder often. A simple list on the wall of what to reorder at what level is enough.
Order a little more before sales, launches or markets.
Growing · 100 to 2,499 units
Set a reorder point for each custom item, because custom lead times are longer. Check stock levels weekly on the same day.
Try this: a sticker or line on the shelf marking the reorder level makes it hard to miss.
Enterprise · 2,500 units and more
Build reorder points into your inventory or purchasing system, using our lead times, and review them before each peak season. Plan longer lead items like rigid boxes and foil printing well ahead.
Keep your packaging specification current so reorders stay consistent.
Common mistakes
- 1Reordering when you run out. By then it's too late for custom packaging. Reorder at your reorder point.
- 2Ignoring lead times. A reorder point that doesn't include the lead time and delivery won't protect you.
- 3No buffer. One busy week or a delay can empty your shelves. Add a buffer.
- 4Storing boxes badly. Damp or crushed stock is wasted stock. Keep it dry, flat and off the floor.
Reorder questions
What is a reorder point?
How do I calculate a reorder point?
How much packaging should I keep on hand?
Do you hold stock for customers?
How should I store flat-packed boxes?
From our customers
The Nonsense MakerWith limited studio space, sourcing locally means faster delivery and less need to store large quantities of bulky boxes.
Read their story →Keep reading
Everyday reorder items
Need help planning your reorders?
Tell us what you use each month. Our Melbourne team will help you work out sensible order sizes and timing, usually within 1 business day.