Shipping is one of the biggest costs for online stores. These ten practical packaging tips reduce costs while keeping products safe and customers happy.
Carriers charge by size as well as weight, so packaging decisions have a direct impact on shipping costs. These ten tips help you save money without risking damaged orders.
1. Right-size every package
Dimensional-weight pricing means you pay for air. Use the smallest box that safely fits the product plus protection.
2. Offer two or three standard sizes
A small set of sizes covers most orders, lets you buy in bulk at better prices and speeds up packing.
3. Use mailers for soft goods
Clothing and textiles rarely need a box. A paper or poly mailer is lighter and smaller – compare options in mailer boxes vs. poly mailers vs. padded bags.
4. Choose the right board grade
Over-specifying board adds weight and cost; under-specifying causes damage. E-flute is often enough for lightweight e-commerce orders. See box materials explained.
5. Replace heavy void fill
Paper fillers and custom inserts weigh less than loose fill and hold products more securely.
6. Seal boxes properly
Good tape prevents failures in transit. Water-activated or reinforced paper tape creates a strong, tamper-evident seal.
7. Print once, use everywhere
One branded mailer design across all sizes is cheaper than many unique designs and still looks professional.
8. Negotiate with carriers
Once your packaging is consistent and right-sized, ask for volume rates.
9. Track damage and returns
Record every damaged order. A small change to packaging often eliminates a recurring problem.
10. Review packaging twice a year
Products, carriers and prices change. A quick review keeps costs under control.
Combined, right-sizing and lighter materials typically reduce shipping spend by 10–20%.
Need help right-sizing your range? Contact our team or explore packaging tapes and mailers.
