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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 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 <\/p>\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 With a smaller, more manageable selection of custom box sizes, there are fewer packing decisions to make and less inventory to store in the warehouse. Using fewer box sizes may also help you enjoy better per-unit pricing.<\/span> <\/span><\/p>\n Always look for opportunities where you can standardize your packaging. For instance, several products may use the same <\/span>product boxes<\/span><\/a> or <\/span>corrugated shipping boxes,<\/span><\/a> allowing you to lower the packaging costs.<\/span><\/p>\n <\/p>\n Reducing package size shouldn’t come at the expense of product protection. Follow these best practices to make sure products remain secure throughout handling and transit:<\/span> <\/span><\/p>\n Match box strength to the product.<\/span><\/b> Heavier or more fragile items may require stronger corrugated material than lightweight, durable products.<\/span> <\/span><\/p>\n Limit movement inside the package.<\/span><\/b> A properly sized box helps keep products from shifting during handling and transportation. If needed, also use cushioning, inserts, dividers, or protective wrapping. These materials help create a snug fit and keep products securely in place during transit.<\/span> <\/span><\/p>\n Test the complete package.<\/span><\/b> Check how well it handles movement, drops, vibration, and other handling and shipping conditions.<\/span> <\/span><\/p>\n <\/p>\n How does box size affect shipping costs?<\/span><\/b> <\/span><\/p>\n When calculating shipping rates, many carriers use dimensional weight, which accounts for how much space a package occupies in addition to its actual weight. Using a box larger than necessary can therefore increase shipping costs, even when the product itself is lightweight. Right-sizing your packaging can help reduce unnecessary space and potentially lower shipping costs.<\/span> <\/span><\/p>\n How can I tell if my shipping box is too large?<\/span><\/b> <\/span><\/p>\n After packing and sealing the box, gently shake it. If the product moves significantly inside the package, there’s probably too much empty space, or it needs additional protection or cushioning. <\/span> <\/span><\/p>\n Should fragile products use smaller shipping boxes?<\/span><\/b> <\/span><\/p>\n A smaller box can reduce movement; however, fragile products need enough room for appropriate cushioning and may require stronger corrugated material, inserts, or other protective packaging. The best box is one that provides a snug fit and adequate protection.<\/span> <\/span><\/p>\n How can standardized box sizes improve fulfillment?<\/span><\/b> <\/span><\/p>\n Using a smaller selection of standard box sizes reduces the number of packaging decisions to make for each order. It can also simplify your inventory and make it easier to establish consistent packing processes.<\/span> <\/span><\/p>\n What packaging should I use for bundles and multi-item orders?<\/span><\/b> <\/span><\/p>\n Start with your actual order history. For example, if your customers frequently purchase the same bundle or product combination, consider giving that order type a dedicated bundle box. This approach is more efficient than automatically moving every multi-item order into your largest box. For less common combinations, choose the smallest standard size in your lineup that provides enough space and protection.<\/span> <\/span><\/p>\n How often should I review my packaging sizes?<\/span><\/b> <\/span><\/p>\n A new bestseller, a popular bundle, a discontinued product, or a major change in product shape or size can be a reason to reassess your box sizes. Conducting an annual review can also help you catch inefficiencies that have developed as your business has grown.<\/span><\/p>\n <\/p>\n The best packaging does more than look good. It protects your products, controls shipping costs, simplifies fulfillment, and creates a better customer experience.<\/span> <\/span><\/p>\n Start with what you ship most, eliminate unnecessary space, and choose packaging that fits your products and protection needs. Then refine your approach as your business grows.<\/span> <\/span><\/p>\n Ready to optimize your packaging? Explore Packlane’s custom packaging options and create a better fit for every order.<\/span> <\/span><\/p>\n[\/et_pb_text][\/et_pb_column][\/et_pb_row][\/et_pb_section]\n<\/body><\/html>\n","protected":false},"excerpt":{"rendered":" As your ecommerce business grows, shipping\u00a0more orders\u00a0is 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>\u00a0<\/span><\/p> An oversized box might not\u00a0seem like a big deal\u00a0when\u00a0you\u2019re\u00a0shipping 50 orders a week. At 500 or 5,000 orders, however,\u00a0you\u2019re\u00a0paying for that extra space that can chip away at your profits. And if products\u00a0aren\u2019t\u00a0packed securely, growth can also mean more damaged shipments, replacements, returns, and disappointed customers.<\/span>\u00a0<\/span><\/p> The solution\u00a0isn\u2019t\u00a0using less packaging\u2014it\u2019s\u00a0using the right\u00a0custom\u00a0packaging\u00a0more efficiently.<\/span>\u00a0<\/span><\/p> By choosing the right box size,\u00a0design,\u00a0and\u00a0packaging 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\u00a0optimize\u00a0their packaging have reduced trailer\u00a0usage by\u00a0around\u00a0<\/span>14%<\/span><\/a>.<\/span>\u00a0<\/span><\/p> Follow these tips to reduce packaging waste, lower shipping costs, prevent product damage, and minimize returns.<\/span>\u00a0<\/span><\/p> \u00a0<\/p> Carriers\u00a0don\u2019t\u00a0always charge based on actual weight alone.\u00a0They may also calculate dimensional weight, which accounts for how much space a package occupies.\u00a0That means a lightweight product shipped in an oversized box can cost\u00a0considerably more\u00a0than the same product packed in a box that fits it properly.<\/span>\u00a0<\/span><\/p> So how do you know whether your packaging is the right size?\u00a0<\/strong><\/p> Start with the smallest package that comfortably fits your product and provides enough protection.\u00a0You\u2019re\u00a0not trying to squeeze an item into the smallest possible box.\u00a0You\u2019re\u00a0trying to\u00a0eliminate\u00a0space that serves no\u00a0purpose.<\/span>\u00a0<\/span><\/p> A simple test is to gently shake the sealed package. If you can hear or feel the product moving significantly,\u00a0there\u2019s\u00a0probably too much\u00a0extra space inside the package.<\/span>\u00a0<\/span><\/p> To start\u00a0right-sizing\u00a0your packaging:<\/span>\u00a0<\/span><\/p> \u00a0<\/p> Having unique packaging for every product may not be\u00a0feasible\u00a0for many brands, especially small and growing ecommerce businesses. A more cost-effective approach is to start\u00a0with a\u00a0small selection of box sizes\u2014i.e., three to five custom box sizes.<\/span>\u00a0<\/span><\/p> For example, your box size options might include:<\/span>\u00a0<\/span><\/p>1. Choose the Right Packaging Size to Lower Shipping Costs<\/span><\/span> <\/span><\/h2>\n
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2. Simplify Your Box Size <\/span>Lineup<\/span> as Your Business Grows<\/span><\/span> <\/span><\/h2>\n
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3. Follow Best Practices <\/span>for <\/span>Product<\/span> Protection<\/span><\/span> <\/span><\/h2>\n
Frequently Asked Questions<\/span><\/span> <\/span><\/h2>\n
Smart Packaging, Better Business <\/span><\/span> <\/span><\/h3>\n
1. Choose the Right Packaging Size to Lower Shipping Costs<\/span><\/span>\u00a0<\/span><\/h2>
2. Simplify Your Box Size\u00a0<\/span>Lineup<\/span>\u00a0as Your Business Grows<\/span><\/span>\u00a0<\/span><\/h2>