Ken Simpson joined computer and consumer electronics manufacturer Belkin, of Rushden, 10 months ago as European regulatory compliance manager.
Part of his role was to evaluate the packaging used by company, whose products range from cables to protective cases for laptop computers. He said: "My background is in environmental management and quality control and I know the various regulations relating to environmental packaging."
By coincidence, soon after his arrival he was contacted by Simon Miller, cleaner design specialist at government agency Envirowise.
Together they developed an alternative design which reduced the overall volume of the packaging used for one of their connectors by 50 per cent.
Mr Simpson said: "Not only has the new design the potential to save us in excess of £200,000 when in full production but it will also decrease the quantity of waste, which everybody pays for in the end."
The reduced size has a knock-on effect; transport efficiency will be doubled – cutting air pollution – retailers will be able to store twice as many products in the same space and there is 50 per cent less waste to get rid of.
Head of quality at Belkin Sari Leino-Huagie said: "We are a global company so we have to think globally and consider our effect on the earth's resources."
It has been estimated the change of packaging will save 18,000kg of paper and 2,400kg of plastic in a year, not to mention a reduction in the annual carbon dioxode emissions of more than 100 tons.
Mr Simpson said: "When you consider the thousands of product lines we carry, the eventual savings to both the company and the environment are incalculable."
A team of Envirowise consultants is now studying a range of Belkin products to see what changes can be made to the packaging. Their findings will be taken to America in February and presented to the people responsible for the packaging designs.
Mr Miller said: "Too many products are surrounded by unnecessary 'air' through over-sized or ill-fitting packaging and some businesses could be doubling their transport costs – as in Belkin's example – simply because a product is over-packed.
"Belkin provides an excellent example of what can be achieved by eliminating unnecessary waste at design stage."
Envirowise is asking businesses in the region to take part in an online challenge, at www.envirowise. gov.uk/howmuchair to find out how much they could save by changing their packaging.