PCRI crest Packaging Clinic &
Research Institute
+91 91608 14321

Packaging Audit and Specification

A deep-dive diagnostic of your packaging ecosystem

A packaging audit is a structured, systematic review of all packaging-related activities in an organisation, from material sourcing to final product dispatch. It identifies improvement areas, cost-saving opportunities and compliance gaps while promoting safety, sustainability and efficiency.

Book an audit Specification development
An auditor reviewing stock in a warehouse

Objectives of a Packaging Audit

What the audit is designed to achieve for your organisation.

  • 01

    Evaluate packaging efficiency

    Assess whether the packaging system is performing well in terms of cost, performance and process.

  • 02

    Ensure compliance

    Verify adherence to applicable legal, safety and regulatory standards such as FSSAI, BIS, ISO and the Plastic Waste Management Rules.

  • 03

    Detect deficiencies

    Identify weaknesses, packaging failures, over-packaging and under-packaging.

  • 04

    Recommend improvements

    Suggest practical changes for material savings, sustainable alternatives and better pack performance.

  • 05

    Support decision-making

    Give management data-backed insights for strategic packaging decisions.

Scope of the Audit

Six areas. The depth in each depends on your products and where the issues are.

01

Material Assessment

  • Type, specification and source of packaging materials used
  • Suitability for product protection and shelf life
  • Opportunities for substitution with bio-based, recycled or recyclable materials
  • Print quality and compatibility with packaging machines
02

Design and Structure Review

  • Ergonomics, strength and stackability
  • Aesthetic appeal and shelf presence
  • Consistency across primary, secondary and tertiary packaging
  • Space utilisation and unit load optimisation
03

Packaging Line and Operations

  • Line layout and efficiency
  • Manual and automated operations
  • Waste generation and rework percentage
  • Storage, handling and transportation issues
04

Compliance and Documentation

  • Labelling as per regulatory requirements such as FSSAI, Legal Metrology and GHS
  • Material safety data sheets (MSDS) and specifications
  • Plastic Waste Management (PWM) and Extended Producer Responsibility (EPR) compliance
  • Use of food-contact safe inks, adhesives and laminates
05

Cost Analysis

  • Per-unit packaging cost breakup
  • Freight and logistics implications of current packaging
  • Over-packaging and material inefficiencies
  • ROI analysis for proposed packaging changes
06

Sustainability Footprint

  • Use of recyclable, reusable or compostable materials
  • Carbon footprint of packaging
  • End-of-life disposal and recyclability analysis

Packaging Specification Development

A specification defines what you buy: the material, grade, dimensions and the test values it must meet. PCRI reviews existing specifications during an audit and develops new ones, backed by laboratory testing, so purchase, quality and suppliers work from the same document.

Discuss a specification
  • Review of existing material and pack specifications
  • New specifications for materials, components and finished packs
  • Test methods and acceptance values written into each specification
  • Alignment of purchase, quality and supplier teams on one document

Tools and Techniques

Visual inspection and samplingOn the line, in the store and at dispatch
Drop, compression and transit testingWhere testing is part of the audit scope
InterviewsWith line supervisors, QC teams and procurement heads
Cost benchmarkingPackaging cost compared against the market
Packaging waste auditType, volume and recyclability of waste
Recording audit findings

Audit Deliverables

  • Packaging Audit ReportObservations and findings, non-conformance and improvement areas, root cause analysis of failures where applicable, and photographic evidence.
  • Recommendations and Action PlanWhat to change, in what order, and the expected benefit.
  • Packaging Compliance ChecklistWhere your packaging and documentation stand against the rules that apply to you.
  • Sustainable Packaging RoadmapWhere applicable, a practical path to less material and better recyclability.
  • Training Need IdentificationThe skills your internal teams need to sustain the improvements.

Who Needs a Packaging Audit?

Any organisation that buys, uses or ships packaging in volume.

  • Food processing units
  • Pharmaceutical manufacturers
  • SMEs and exporters
  • E-commerce brands
  • Warehousing and distribution hubs
  • CSR programmes and NGOs working on packaging hygiene and safety

Audit Frequency

Option 1

One-time

During product launches, certifications or troubleshooting.

Option 2

Periodic

Annual or half-yearly reviews.

Option 3

Continuous

For large operations with an in-house PCRI presence.

Why PCRI for a Packaging Audit?

An independent institute with its own laboratory, education programme and consultancy practice behind every audit.

  • Decades of packaging expertise
  • Cross-sector knowledge across food, pharma, industrial and FMCG
  • A strong focus on compliance and sustainability
  • Access to a network of testing laboratories for material validation
  • An approach shaped to your budget and scale

Book a Packaging Audit

Tell us what you make and where you make it. We will scope the audit and explain what it involves before anything is committed.

  • Someone from the team will call or write back on the next working day.
  • Prefer to talk? Call or WhatsApp +91 91608 14321.

Request a Quote

Thank you. Your request is with PCRI.

Someone from the team will call or write back on the next working day.