When a brochure, carton, or influencer kit creates more waste than expected, the cause may trace back to a decision made long before production: an oversized format, an extra insert, a last-minute change, or a box with more empty space than product.
That gives print buyers an opportunity. By involving their printer earlier, they can make choices that use less material while still delivering the look and experience the project needs.
Start with size. Could a slightly smaller brochure fit more efficiently on a press sheet? Could a product tray hold everything securely without a larger outer box? Even small adjustments can add up across a production run. The U.S. Environmental Protection Agency ranks reducing waste at its source above recycling in its waste management hierarchy.
Then look at what the piece is made of. Recycled-content and FSC®-certified papers are options to discuss with your printer, along with the weight of the stock and the finishes you want to use. FSC certification addresses responsible sourcing and provides a documented chain of custody for certified materials.
According to the American Forest & Paper Association, the U.S. recycled approximately 45 million tons of paper in 2025, and the estimated cardboard recycling rate was 70% to 75%. But a high recycling rate does not mean every printed piece or custom box can go in the recycling bin. Coatings, laminates, windows, and other design choices can affect what local programs accept. Talk through those details with your printer before the design is final.
A Greener Project Starts With the Buyer
Bring production into the design conversation. A dramatic reveal can make an influencer kit memorable, but it also needs a structure that cuts, folds, assembles, protects the products, and ships well. An early review of the dieline and materials gives the team a chance to solve problems before final art, proofs, or inventory are committed.
Shipping deserves that same early attention. A box with unnecessary space uses more material and may cost more to send: USPS applies dimensional-weight pricing to qualifying large, lightweight parcels. Right-sizing the shipper and planning deliveries together can help the project beyond the pressroom.
There is no single specification that makes every print project sustainable. The useful question is more specific: What can we change in this project to reduce waste without compromising its purpose?
When buyers and printers act like a team, sustainability stops being a buzzword and becomes a practical workflow: less waste, fewer surprises, and print that looks great and feels responsible. Calitho is ready to support your next project, let’s get started today!