A packaging sustainability audit isn’t as scary as it sounds; it’s a structured review of your entire packaging system to understand its environmental impact and identify opportunities to reduce waste and improve performance. Rather than focusing on a single material or product, it considers how all the pieces work together, and where they fall short.

At a minimum, a packaging sustainability audit dials in on:

• Materials – what your packaging is made from and how much recycled content it contains

• Formats – the types of packaging you use, from mailers and boxes to void fill and labels

• Sourcing – where and how your packaging is manufactured

• End-of-life pathways – how you can realistically reuse, recycle, or dispose of each component

If you’re new to this process, a shared definition of what “sustainable packaging” actually means (and what it doesn’t) is a great starting point. We break that down in more detail in Understanding Sustainable Packaging: What It Is and Why It Matters, which provides helpful context before diving into an audit.

Just as important is knowing that a packaging sustainability audit isn’t a one-time materials swap or a green-marketing exercise. Changing a single component without understanding the full system can create new tradeoffs, higher costs, operational friction, or packaging that’s harder for customers to dispose of correctly. So let’s avoid that.

A well-run audit gives you clarity. It helps you identify your biggest impact drivers, prioritize realistic improvements, and make packaging decisions that support your sustainability goals and your business in 2026.

Before you can improve your packaging, you need a clear picture of what you’re actually using today. This step sounds obvious, but it’s the one most teams rush through, and it’s where the biggest insights usually live.

So start by mapping your entire packaging system, not just the box or mailer customers see.

Your packaging system checklist:

• List every packaging component used for each shipment (primary, secondary, and tertiary packaging)

• Identify materials, coatings, adhesives, and inks for each component

• Note where each item is sourced and manufactured

• Track volumes and usage by SKU, including seasonal or promotional variations

If you don’t already have this documented, building a simple packaging bill of materials can make the process way easier. Our packaging Bill of Materials tool is a helpful starting point for organizing components, materials, and quantities in one place.

This step also helps expose inefficiencies you aren’t aware of, like redundant inner packaging, mixed materials that complicate recycling, or components that are overused for certain SKUs. For a broader look at how all these elements fit together in a modern shipping operation, the Definitive Guide to eCommerce Packaging offers additional context and examples.

Want a pro tip? Resist the urge to jump straight to solutions. A well-mapped packaging system sets the foundation for every improvement that follows, and ensures your sustainability efforts are grounded in reality, not assumptions.

Once you’ve mapped your packaging system, you need to figure out where change will actually matter. Not every component carries the same environmental weight, and chasing small optimizations can take your eye off of bigger opportunities.

In most packaging systems, the largest sources of waste and impact tend to fall into a few categories that are probably familiar:

• Overbuilt boxes that use more material than the product requires

• Mixed-material formats that are difficult to recycle or separate

• Excess void fill added out of habit rather than necessity

• Low recycled content where higher-recycled alternatives exist

This is where asking the right questions helps surface real insights, especially if you’re reviewing data across multiple SKUs or fulfillment workflows.

Ask yourself:

• Which packaging component creates the most waste per shipment?

• Where are we using plastic by default, not because it’s truly required?

For a lot of brands out there, right-sizing packaging is one of the fastest ways to reduce material use, shipping emissions, and damage rates at the same time. The Right-Size Packaging Guide breaks down how to evaluate box dimensions and choose sizes that are a better match for your products.

Void fill is another common culprit. If you’re relying heavily on plastic cushioning, it may be worth exploring lower-impact alternatives that still protect your products in transit. Finding an Alternative to Bubble Wrap® walks through practical options and the tradeoffs to consider.

The goal of this step isn’t to eliminate every imperfect material, it’s to identify the few decisions that drive the majority of your packaging waste, so you can focus your 2026 efforts where they’ll have the biggest payoff.

Sustainability claims matter, but only if they hold up in the real world. As regulations tighten and consumers grow more skeptical, vague or oversimplified messaging can do more harm than good. In 2026, “keeping it real” isn’t just good practice, it’s increasingly required.

Pressure-testing your packaging claims means asking whether they’re specific, accurate, and useful, not just well-intentioned.

Start with a few grounding questions:

• Are our claims clearly defined and fact-based? Broad statements like “eco-friendly” or “green” don’t give customers enough information to understand impact.

• Do our claims match how customers can actually dispose of the packaging? A material that’s technically recyclable isn’t very helpful if most customers don’t have access to the right recycling stream.

• Are we honest about tradeoffs? No packaging solution is perfect, and clarity builds more trust than perfection ever could.

This step is also where certifications can play a helpful role, when they’re available and relevant. Third-party certifications can add credibility and clarity to certain claims, but they’re not required for every sustainable packaging choice. What matters most is that any claim you make is accurate, supportable, and appropriate for the material and context. EcoEnclose’s Guide to Sustainable Certifications breaks down when certifications are useful, what they signal, and where they may not be necessary.

It’s also important to account for new packaging legislation, especially SB 343 Truth in Labeling, which goes into effect this year. SB 343 tightens the rules around recyclability claims, requiring that labels reflect real-world recycling access, not just technical recyclability. What SB 343 Means for Your Sustainable Packaging explains how this impacts packaging claims, labeling language, and compliance risk.

If you’re unsure where your messaging might cross into greenwashing territory, EcoEnclose’s Greenwashing Explained guide outlines common pitfalls and how to avoid them, especially in packaging, where claims are often misunderstood or oversimplified.

Finally, it’s critical to distinguish between packaging that is recycled and packaging that is recyclable, two terms that are often used interchangeably but mean very different things. Recycled vs. Recyclable: What’s the Difference and Why It Matters provides a clear explanation to help ensure your claims align with reality.

Pressure-testing your claims isn’t about dialing back your sustainability story. It’s about telling it well, so customers know exactly what they’re getting, regulators have fewer questions, and your packaging decisions stand up over time.

Fact: Sustainable packaging only works if it performs in the real world. If a change slows down packing, increases damage, or creates new operational headaches, it’s unlikely to stick, no matter how good it looks on paper.

That’s why material optimization should start with improvements that reduce impact without disrupting your workflow.

Material optimization checklist:

• Increase recycled content first. In many cases, switching to higher–recycled-content materials delivers meaningful impact reductions with minimal operational change.

• Simplify material structures. Fewer layers and fewer material types make packaging easier to recycle and easier to manage in fulfillment.

• Avoid changes that increase damage or slow packing. Sustainability gains disappear quickly if returns, reships, or labor costs rise.

Recycled content is often one of the easiest wins because it lowers environmental impact without changing how packaging is used or disposed of. If you’re evaluating where recycled content delivers the most value, Why Recycled Content Matters breaks down the benefits and tradeoffs in clear, practical terms.

Protection still matters, especially for fragile or high-value products. If you’re looking to reduce plastic while maintaining performance, Eco-Friendly Protective Packaging Options outlines paper-based and lower-impact cushioning alternatives, and where each one works best.

Circular packaging is often treated as the end goal, but in practice, it only works when real-world systems are in place to support it. Designing for circularity isn’t about choosing the most aspirational option; it’s about choosing the option that has the highest chance of actually being recovered, reused, or recycled, at scale, and by real people.

A few realities to keep in mind:

• Recycling access varies widely (understatement). What’s recyclable in one city may not be accepted in another, especially for specialty or mixed materials.

• Composting isn’t universal. Industrial composting infrastructure is limited, and many customers don’t have access, or aren’t sure how to use it.

• Reuse only works with infrastructure. Reusable packaging requires reverse logistics, customer participation, and systems that make returning packaging easy and worthwhile.

This is why circularity works best when packaging is intentionally designed to fit existing recovery systems. Reuse can be powerful, but only in the right contexts. If you’re exploring reusable mailers or take-back models, When to Consider Reusable Packaging for eCommerce breaks down when reuse makes sense, what infrastructure is required, and where it can fall apart.

Sustainable packaging decisions need to support where your business is headed, not just where it is today. Pressure-test your packaging choices against your 2026 goals and make sure they can scale alongside your brand.

As you evaluate options, consider how packaging supports three key areas:

• Growth and scaling. Will this packaging still work as volumes increase, SKUs expand, or fulfillment becomes more complex?

• Retail expansion. Does it meet retailer guidelines, shelf requirements, and durability standards for in-store environments?

• Brand storytelling. Does your packaging clearly communicate your values, without overclaiming or overwhelming the design?
  
  

Regulatory readiness is becoming a bigger part of packaging strategy, especially as Extended Producer Responsibility (EPR) programs expand. Our EPR Packaging Requirements resource offers a practical overview of what brands need to know and how to prepare without overcorrecting.

Aligning packaging with your 2026 business goals ensures your sustainability efforts aren’t just well-intentioned, they’re durable, defensible, and designed to grow with you. Onward and upward!

Once you’ve completed your audit and identified your biggest opportunities, turn your insights into action with a packaging sustainability plan that’s phased, flexible, and grounded in reality.

Your 2026 packaging roadmap might include:

• Quick wins that deliver immediate impact with low cost and minimal disruption, like increasing recycled content or right-sizing packaging for top SKUs

• Mid-term projects that require more planning, such as changing packaging formats, simplifying material structures, or updating supplier relationships

• Long-term efforts that support deeper impact over time, including custom packaging, reuse programs, or piloting innovative materials

This approach keeps momentum high while giving your team space to test, learn, and adjust.

Not every initiative needs to launch next week, and that’s okay because progress beats perfection. Having a plan that your team can execute and sustain as your business grows is key.

If you’d like a second set of eyes on your roadmap, or help prioritizing next steps, our team can support you wherever you are in the process. Start a conversation here.

A strong sustainability strategy isn’t about having all the answers. It’s about asking the right questions, making informed decisions, and building a packaging system that improves year over year. That New Year’s resolution is looking good already.

What should be included in a sustainable packaging checklist?

A sustainable packaging checklist should look at your entire packaging system, not just individual materials. That includes auditing materials, formats, sourcing, and end-of-life outcomes, then prioritizing changes based on real impact and feasibility. Starting with a structured audit and using a clear framework helps ensure decisions are grounded in both sustainability and operations. EcoEnclose’s Packaging Bill of Materials and Sustainable Packaging Framework are helpful tools for organizing this process.

What’s the easiest way to reduce packaging waste in 2026?

For most brands, the fastest wins come from right-sizing packaging and increasing recycled content. Using boxes and mailers that better match product dimensions reduces material use and shipping emissions, while higher recycled content lowers overall environmental impact without changing fulfillment workflows. The Right-Size Packaging Guide and Why Recycled Content Matters break down how these changes deliver measurable benefits.

How do I avoid greenwashing in packaging claims?

Avoiding greenwashing starts with being specific, accurate, and transparent. Claims should reflect how packaging is actually used and disposed of by customers, and they should acknowledge tradeoffs where they exist. EcoEnclose’s Greenwashing Explained guide outlines common pitfalls, while the Certifications page explains when third-party verification is available, and when clear, well-supported claims are still appropriate.

Do I need fully recyclable or compostable packaging to be sustainable?

Not necessarily. Sustainability depends on context, including available infrastructure, customer behavior, and packaging performance. Packaging made with recycled content or designed for reuse can be highly effective even if it isn’t universally recyclable or compostable. Understanding the difference between recyclable and compostable materials, and where each makes sense, is key.

How do packaging laws like EPR and SB 343 affect sustainability decisions in 2026?

Packaging legislation is becoming a bigger driver of sustainability strategy, especially with Extended Producer Responsibility (EPR) programs expanding and SB 343 Truth in Labeling rules reshaping how recyclability claims can be made. In practice, this means brands need to pay closer attention to material choices, labeling accuracy, and documentation, not just environmental impact.

EPR laws typically require brands to report on packaging materials, pay fees based on recyclability and volume, and plan ahead for compliance across multiple states. EcoEnclose’s EPR Packaging Requirements resource offers a practical overview of what brands should track and how to prepare.

SB 343, meanwhile, focuses on truth in labeling, tightening the rules around when packaging can be labeled as “recyclable.” Claims now need to reflect real-world recycling access, not just technical recyclability. What SB 343 Means for Your Sustainable Packaging breaks down how this impacts materials, messaging, and risk.

Together, these laws reinforce an important point: sustainable packaging in 2026 isn’t just about choosing better materials, it’s about making decisions that hold up operationally, environmentally, and legally.