Packaging and more specifically environmentally friendly packaging has received considerable attention over the years. This paper seeks to provide an investigation into the issue of overpackaging regarding the outer paper packaging box and the various implications coming from the use of overpackaging in a company’s operations. A practical case study has been analysed in which two paper packaging design options of the same corrugated box are investigated in terms of: paper quality and final packaging cost. The case study is followed by a detailed comparison between two selected options, in order to show the strengths and weaknesses involved in each case. The results provide significant evidence that a thorough investigation of the overpackaging issue, has the potential to bring economic benefits to a company where the protection of the product carried is ensured, the logistics activities are facilitated, the informative role of packaging is to the required standard and the cost is maintained low. The paper contributes by providing an environmentally and economically sustainable solution to paper packaging companies interested in improving the outer packaging design. The paper brings theoretical consideration to the issues of overpackaging by moving forward the research agenda of economically and environmentally sustainable packaging.