Sustainable Packaging & EPR Compliance worked example

Lightweighting Savings at 99% share of theoretical savings actually realized: a worked example

Push share of theoretical savings actually realized up to 99% and the picture changes. This example computes every intermediate figure at that operating point. A packaging engineer evaluating whether downgauging or redesigning a format pays back the one-time qualification investment.

The inputs for this scenario

  • Packaging material removed across the run: 8,000 kg (unchanged)
  • Delivered material cost avoided: 2.1 $/kg (unchanged)
  • Share of theoretical savings actually realized: 99 % (raised for this scenario; the documented default is 90)
  • Redesign and requalification cost (enter as negative): -3,500 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Net savings = weight removed x cost per kg x realized% + redesign cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 16,632 $ for total lightweighting savings cost, the number this scenario is built around.
  • At this operating point the engine returns 2.08 $ / piece for lightweighting savings cost per unit.
  • At this operating point the engine returns 16,632 $ for variable lightweighting savings cost.
  • At this operating point the engine returns 0 $ for fixed lightweighting savings adder.

How this compares with the baseline

  • Against the tool's baseline example, where share of theoretical savings actually realized sits at 90% and the headline result is 15,120 $, this scenario comes in 10% above the baseline at 16,632 $.
  • It nets the realized material cost removed by lightweighting against the one-off redesign and qualification spend, and expresses the result per kilogram removed. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Total lightweighting savings cost: 16,632 $ (headline result)
  • Lightweighting savings cost per unit: 2.08 $ / piece
  • Variable lightweighting savings cost: 16,632 $
  • Fixed lightweighting savings adder: 0 $

Run it with your numbers

  • Every input above is editable in the live Lightweighting Savings calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.