Why Packaging Needs to Catch Up

In recent conversations with both global FMCG firms and high-growth nutraceutical startups, one challenge keeps surfacing: packaging is lagging the rest of the supply chain.

Earlier this year, we worked with a client preparing to launch a personalized subscription product across multiple markets. Formulations were finalized; marketing was locked in—but a last-minute regulatory update required changes to their packaging artwork. Because the corrugate boxes were pre-printed weeks in advance, everything stalled. The delay cost them a high visibility launch window.

Scenarios like these highlight a deeper issue: traditional packaging workflows—planned early, printed in bulk, and forecasted far in advance—no longer align with today's market dynamics.

The Problem with Early Packaging Decisions

We've seen how early-stage packaging commitments introduce rigidity and risk into otherwise agile operations. Among the most common pain points:

• Obsolete inventory from outdated SKUs or artwork
• Launch delays caused by inflexible packaging timelines
• Packaging complexity due to managing high volumes of printed variants

As brands race to respond to customer preferences, regulatory changes, and sustainability goals, packaging must evolve from a bottleneck into a strategic advantage.

Late Varianting: A Smarter Way to Print Corrugate

At Packfora, we've been helping clients transition to a more agile packaging model through Late Varianting.

Late Varianting refers to on-demand digital printing of corrugate boxes at the end of the production process. Instead of relying on pre-printed packaging sourced weeks in advance, manufacturers use blank substrates and apply final artwork just before shipment.

This approach allows teams to:

• Delay final artwork decisions until product configuration is complete
• Standardize materials and reduce printed SKU count
• Adapt packaging to market-specific messaging or compliance requirements

What's Fueling the Shift

Several macro trends are accelerating the adoption of on-demand packaging:

? SKU Proliferation

With personalization, seasonal launches, and region-specific variants, packaging portfolios are expanding. A NielsenIQ report found a 32% rise in SKUs across North American shelves over five years.

? Faster Design Cycles

Packaging now serves as a marketing canvas—driving QR-led engagement, limited edition campaigns, and co-branding opportunities. Traditional timelines simply can't keep pace.

? Regulatory Volatility

Especially in pharma and consumer health, last-minute label changes are common. With Late Varianting, updates can be executed days—not weeks—before delivery.

?? Sustainability Pressures

Over-ordering to meet minimum print quantities leads to material waste. Digital corrugate printing cuts excess and supports circular economy targets.

Where Late Varianting Makes an Impact

Late Varianting is most effective when applied strategically, not universally. Based on our work across categories, here's where we see it delivering the strongest value:

What Makes It Work: Key Enablers

Implementing Late Varianting at scale requires the right blend of technology and process alignment:

? High-Speed Digital Corrugate Printers

Installed near or on the packing line, these printers apply full-color graphics in real time using CMYK or extended gamut inks.

? Artwork Automation & Smart Data Layers

We help integrate artwork libraries with rule-based logic, dynamically matching designs to SKUs, regions, or campaigns.

? QA & Compliance Integration

Print workflows are embedded with version control, audit trails, and pre-press validation—ensuring accuracy, traceability, and regulatory alignment.

Tangible Results from the Field

According to McKinsey, companies that digitize supply chain functions—like packaging—can reduce time-to-market by up to 50%. That's a powerful stat in markets where speed equals revenue.

Our clients have experienced:

• 80-90% reduction in obsolete packaging inventory
• 20-30% faster readiness for new SKU launches
• Improved sustainability metrics via reduced overproduction

Beyond efficiency, the real win is control—control over timelines, compliance, and creative execution at the final mile of production.

How Packfora Helps Brands Deploy Late Varianting

We embed Late Varianting within our broader Print & Artwork Optimization framework, designed to modernize how brands manage graphics, prepress, and packaging control.

Our approach includes:

• Feasibility assessments based on your production mix, SKU volume, and market strategy
• Printer selection and integration planning
• Workflow automation for artwork assignment, approvals, and compliance assurance
• Training and change management to drive adoption across stakeholders

This is not a plug-and-play solution—it's a transformation of how packaging gets done.

Closing Thought: Print at the Speed of Business

Late Varianting isn't a passing trend—it's a strategic response to the evolving demands of packaging operations. In markets where speed, compliance, and sustainability define success, printing corrugate at the point of readiness offers a clear edge.

For teams navigating increasing SKU complexity or tightening sustainability mandates, this shift offers measurable gains—and a smarter way to work.

? Let's Reimagine How Your Boxes Get Printed

Curious whether Late Varianting is right for your supply chain?

Get in touch with Packfora's experts to assess your current setup and identify opportunities for transformation—one box at a time.