1. Relying on Supplier Estimates

Many businesses rely on supplier-provided weights without verification.

❌ Why this is risky: supplier data may be outdated, estimated, missing components, or not SKU-specific.

⚠ Risks: incorrect reporting, fee errors, audit failure, and backdated penalties.

✅ Fix: physically weigh packaging, document methodology, update regularly, and store evidence.

🔗 UK pEPR Reporting Guide 2026

🔗 How to Pass a Packaging Compliance Audit

2. Ignoring Tertiary and Transit Packaging

Most businesses overlook pallet wrap, shipping boxes, tape, labels, void fill, and other transit materials.

❌ Why this matters: these materials often count toward reporting and fees.

✅ Fix: audit all packaging layers: primary, secondary, tertiary, and ecommerce packaging.

🔗 Packaging Audit Checklist UK

3. Missing Supplier Evidence

Assuming suppliers are compliant without proof is a major mistake.

❌ Why this is risky: you cannot prove material composition, recyclability, certifications, or claims.

✅ Fix: request technical specs, material declarations, recycled content proof, and certifications.

📥 Supplier Evidence Tracker

4. Ignoring pEPR Fee Modulation

Under pEPR, costs depend on packaging performance, not just weight.

❌ Common mistake: treating all packaging as equal cost.

⚠ Risk: higher long-term costs and poor packaging decisions.

✅ Fix: identify high-cost materials, model fee impact, and prioritise redesign for high-risk formats.

🔗 UK pEPR Fees Explained

💷 EPR Fees Cost Planner

5. Poor Recyclability Design

Design decisions directly affect both compliance and cost.

❌ Problem packaging: multi-material packs, dark plastics, non-detachable components.

⚠ Risks: higher fees, lower recyclability scores, and retail rejection.

✅ Fix: use mono-materials, simplify packaging, and align design with real recycling systems.

🔗 Recyclability Scores Explained

6. Weak Audit Preparation

Many businesses only prepare when audited, which is too late.

❌ Why this fails: audits require evidence, traceability, and documentation ready on demand.

⚠ Risks: failed audits and enforcement action.

✅ Fix: maintain audit-ready files, keep structured records, and run internal audits regularly.

🔗 Packaging Audit Guide UK

7. Incorrect Labelling

Labelling errors are increasingly scrutinised by regulators and retailers.

❌ Issues include incorrect recycling labels, missing EU requirements, and unsupported claims.

⚠ Risks: retailer rejection and potential legal issues.

✅ Fix: verify all claims, align labels with national and EU regulations, and review EU requirements for exports.

🔗 EU Packaging Labelling Guide

8. Ignoring EU PPWR Requirements

Many UK businesses forget that export compliance matters too.

❌ Why this matters: PPWR applies to EU sales, marketplaces, and retail partners.

⚠ Risks: shipment delays, product rejection, and compliance fines.

✅ Fix: separate UK vs EU SKUs, review packaging design for EU markets, and prepare documentation.

🔗 PPWR Timeline Explained

🔗 PPWR for UK Exporters

9. No Packaging Register

Without a central packaging register, data becomes inconsistent and incomplete.

❌ Problems: missing packaging, duplicate data, and poor traceability.

✅ Fix: create a packaging register including SKU, material, weight, supplier, and market.

📥 pEPR Reporting Guide

10. No Ownership of Compliance

When everyone owns it, no one owns it.

❌ Result: gaps in data, missed deadlines, and poor coordination.

✅ Fix: assign a clear compliance owner, define responsibilities, and schedule regular reviews.

11. Not Tracking Packaging Changes

Packaging changes happen frequently through suppliers and internal updates.

❌ Risk: outdated data and incorrect reporting.

✅ Fix: track supplier changes, material updates, and weight changes, and update records promptly.

12. Treating Compliance as One-Off

The biggest mistake is treating compliance as a one-off task rather than an ongoing system.

❌ Why this fails: regulations, fees, and evidence expectations change constantly.

✅ Fix: build a system with quarterly reviews, ongoing updates, and continuous improvement.