The Benefits of Downgauging
Last Updated on April 20, 2026 by Kira Andrus
At ClearBags, we are committed to packaging with purpose. Whatever your purpose, your packaging should meet the needs of your product. One way to achieve this is through downgauging – a strategy to reduce costs, enhance operations, and support sustainability for your business. In this article, we will discuss the benefits of downgauging with an emphasis on evaluating your needs and factoring in consumer perception.
What is downgauging?
Downgauging is reducing the thickness (gauge) or size of packaging materials. This is most often seen when using plastic packaging, and is driven by the desire to reduce costs and promote sustainability. This growing trend focuses on reducing plastic consumption and minimizing waste while maintaining or even improving performance.
Why should you downgauge?
There are several reasons why companies are pursuing downgauging, but the overarching reasons are to save costs and improve their sustainability profiles. Advances in technology and material science have created stronger plastics with increased flexibility, all while reducing plastic use and carbon emissions. With less packaging material being used for each product, there is less waste at both the production and consumer levels. With less expense in raw materials and shipping/storage costs, downgauging packaging also helps reduce overhead.
What should you consider when downgauging?
Most people don’t have a lot of experience with downgauging, so if you decide you want to downgauge you need to do some research. First, consider your product and what value – shelf life and/or perception – might be diminished with downgauging. Then, look at your current packaging.
Protecting and Preserving Products
If your product has a limited shelf life (i.e. food products), reducing packaging could mean reducing barriers meant to protect and prolong the shelf life of your product. This is especially true for heavier products where seams need reinforcement. Less raw material can mean the packaging is weakened. Determine what packaging products will support both the shelf life of your product and the weight. Often, a coated material can provide the barrier you need for protection of the product and preservation. This is seen in stand up zipper bags where an additional barrier is used to keep products fresher longer. If you downgauge a bag (say from 4 to 3 mil) but you add a barrier, you can achieve the same shelf life. The barrier adds no thickness, but it provides greater protection at a lighter weight.
Consumer Perception
In today’s economy, no one wants to purchase a smaller bag at the same or a higher price, so take the time to educate consumers on how and why you are reducing packaging waste. When opting for smaller packaging with less wasted space around your product, leave room for important details including advertising your commitment to quality products in smaller packaging. You also want your label to be prominent, so factor in your branding. It can be done on packaging of less size, but you want to make sure you don’t lose space or 25% of your advertising, instructions, etc. on your product. Using less ink is a positive, so get creative with QR codes and labels that convey information in a smaller space.
One good thing you achieve with downgauging is greater clarity than you can get with thicker plastic materials. Clarity has value, and high clarity makes products look more expensive. ClearBags Crystal Clear Bags are a popular product made of Biaxially Oriented Polypropylene (BOPP) and Orientated Polypropylene (OPP) – plastic films that are stretched so the microscopic fibres are aligned, creating a clear plastic film that is thin, strong, and crystal clear. Using materials that are less bulky and wasteful show refinement and care, appealing to consumers looking for a high-end product at a better value.
Environmental Impact
The Technical Association of the Pulp & Paper Industry Inc. (TAPPI) – a not-for-profit, international, non-governmental organization – has been following the trend in plastic use. TAPPI reports “the typical thickness of industrial stretch film has been reduced by approximately 25%” in the last decade. This finding is significant because the reduction saves an estimated “1 billion pounds of polyethylene each year”. With the raw materials not being used, transported, processed, or disposed of in a landfill, that “translates into … 293 million gallons of gasoline” (tappi.org). Advancements in plastic technology are creating thinner plastics that are also stronger with strong barrier properties. The advancements in monomaterial structures means these new plastics are lighter to ship, strong enough to hold your products, and eco-friendly for recycling.
How do I get started with downgauging?
Determine first what you are packaging and what you need. Think about both the weight of your current packaging and your product. Do you have a heavy product? Do you need a barrier? Let consumers know ahead of time what you are planning to do. Let them know you are downgauging to protect the environment and use less material. Think outside the box! Maybe downgauging means using a stronger bag (even thicker but not as tall as your current packaging). Reducing the height of the bag could use up to 25% less packaging – the contents haven’t changed, but the bag did.
Get ahead of the game so consumers can look forward to what you are doing and your efforts to be more environmentally friendly. Let them know they will get the same amount with less packaging. After time, you won’t have to convey the change on your packaging anymore, and you won’t lose loyal customers. Get buyers to buy into what you are doing.
Do you have more questions on how you can downgauge your packaging materials? Contact us at clearbags.com.
