1. Using Oversized Boxes
Extra space means higher shipping costs and more void fill needed. It also increases the risk of items shifting during transit. Invest in multiple box sizes to match your product range.
2. Insufficient Cushioning
Trying to save on bubble wrap or packing peanuts often backfires. The cost of one damaged item usually exceeds what you’d spend on proper cushioning for dozens of shipments.
3. Ignoring Weight Distribution
Heavy items at the bottom, fragile items on top, with proper separation between layers. This basic principle prevents damage and makes unpacking easier for customers.
4. Poor Tape Quality
Cheap tape might save pennies but can fail during transit. Use proper packing tape and apply it correctly – H-taping method provides the best seal for most boxes.
5. Inconsistent Processes
When each team member packs differently, quality varies. Standardize your procedures and provide clear guidelines for all staff.
6. Forgetting the Unboxing Experience
Packaging is a marketing touchpoint. Damaged outer boxes, excessive tape, or messy presentation affects brand perception even if the product arrives safely.