{"id":233980,"date":"2026-08-24T20:56:21","date_gmt":"2026-08-24T20:56:21","guid":{"rendered":"https:\/\/packlane.com\/blog\/?p=233980"},"modified":"2026-08-24T20:56:21","modified_gmt":"2026-08-24T20:56:21","slug":"how-better-packaging-can-reduce-shipping-costs-and-product-damage","status":"publish","type":"post","link":"https:\/\/packlane.com\/blog\/how-better-packaging-can-reduce-shipping-costs-and-product-damage\/","title":{"rendered":"How Better Packaging Can Reduce Shipping Costs and Product Damage"},"content":{"rendered":"\n

As your ecommerce business grows, shipping more orders is usually a sign that things are going well. But higher order volume can also make even the smallest packaging inefficiencies and oversights more expensive.<\/span> <\/span><\/p>\n

An oversized box might not seem like a big deal when you’re shipping 50 orders a week. At 500 or 5,000 orders, however, you’re paying for that extra space that can chip away at your profits. And if products aren’t packed securely, growth can also mean more damaged shipments, replacements, returns, and disappointed customers.<\/span> <\/span><\/p>\n

The solution isn’t using less packaging—it’s using the right custom packaging more efficiently.<\/span> <\/span><\/p>\n

By choosing the right box size, design, and packaging materials, you can lower the fulfillment costs and reduce wasted space in the warehouse and transit, allowing more products to fit per truckload. Businesses that optimize their packaging have reduced trailer usage by around <\/span>14%<\/span><\/a>.<\/span> <\/span><\/p>\n

Follow these tips to reduce packaging waste, lower shipping costs, prevent product damage, and minimize returns.<\/span> <\/span><\/p>\n

 <\/p>\n

1. Choose the Right Packaging Size to Lower Shipping Costs<\/span><\/span> <\/span><\/h2>\n

Carriers don’t always charge based on actual weight alone. They may also calculate dimensional weight, which accounts for how much space a package occupies. That means a lightweight product shipped in an oversized box can cost considerably more than the same product packed in a box that fits it properly.<\/span> <\/span><\/p>\n

So how do you know whether your packaging is the right size? <\/strong><\/p>\n

Start with the smallest package that comfortably fits your product and provides enough protection. You’re not trying to squeeze an item into the smallest possible box. You’re trying to eliminate space that serves no purpose.<\/span> <\/span><\/p>\n

A simple test is to gently shake the sealed package. If you can hear or feel the product moving significantly, there’s probably too much extra space inside the package.<\/span> <\/span><\/p>\n

To start right-sizing your packaging:<\/span> <\/span><\/p>\n

    \n
  1. Measure your three to five best-selling products or product bundles first. The packaging savings can add up when applied across hundreds or thousands of high-volume orders.<\/span> <\/span><\/li>\n
  2. Match each product to the smallest <\/span>shipping box<\/span><\/a> or <\/span>mailer box<\/span><\/a> that provides adequate protection.<\/span> <\/span><\/li>\n
  3. Check how much void fill you’re using and whether a smaller package could do the same job.<\/span> <\/span><\/li>\n
  4. Look for a custom packaging supplier that offers low minimum orders so you can test a new box size or design.<\/span> <\/span><\/li>\n<\/ol>\n

     <\/p>\n

    2. Simplify Your Box Size <\/span>Lineup<\/span> as Your Business Grows<\/span><\/span> <\/span><\/h2>\n

    Having unique packaging for every product may not be feasible for many brands, especially small and growing ecommerce businesses. A more cost-effective approach is to start with a small selection of box sizes—i.e., three to five custom box sizes.<\/span> <\/span><\/p>\n

    For example, your box size options might include:<\/span> <\/span><\/p>\n