Every online order you send passes through sorting hubs, conveyor belts, delivery vans and a few drops along the way. Packaging that's too weak means broken products, refunds and bad reviews. Packaging that's too big means you pay to ship air. Here's how to pack e-commerce orders so they arrive safely and cost less to send.
1. Right-size the box first
Most couriers charge by whichever is greater: the parcel's actual weight or its volumetric weight. Volumetric weight is usually worked out as length × width × height in centimetres, divided by a factor such as 5,000 or 6,000. The factor depends on your courier, so check your rate card.
That means an oversized box can cost you more to ship than the product weighs. A carton that fits the product, with just enough room for cushioning, is cheaper to ship, needs less void fill and protects better because nothing can slide around.
2. Choose the right type of box
- Mailer (airplane) boxes are die-cut, fold together without tape, and give a neat unboxing. They're ideal for apparel, cosmetics, books and gift items. See our die-cutting service.
- Standard RSC cartons suit multi-item orders and heavier goods, and are the most economical per box. See our carton boxes.
- Single or double wall? Single wall handles most parcels. Step up to double wall for heavy or very fragile items. Our single wall vs double wall guide explains when.
3. Cushion and fill the gaps
Damage in transit usually comes from two things: impact (drops and knocks) and movement (the product sliding around inside the box). Use the right material for each:
| Material | Best for | Use it for |
|---|---|---|
| Air bubble wrap | Shock and drops | Glass, ceramics, electronics (anti-static grade), anything fragile. Also comes as ready-made bubble bags |
| Single facer roll | Wrapping and void fill | Wrapping bottles and boxed products, filling gaps so items can't shift. Paper-based and recyclable |
| PE foam | Scratch protection | Wrapping polished or painted surfaces, and layers between stacked items |
Then do the shake test: close the box and shake it gently. If you can feel or hear the product move, add more fill.
Keep fragile items at least a few centimetres away from every wall of the box, with cushioning on all sides, including the bottom and top.
4. Seal it properly
Use proper OPP carton-sealing tape, not office tape. Tape the centre seam on the top and the bottom, then run tape across both edge seams. This is the "H" pattern, and it stops flaps from popping open when the box is squeezed in a courier sack. Heavier boxes deserve a second strip. See our packaging tapes.
5. Label it so it isn't misrouted
- Put the shipping label on the largest flat surface, away from seams and edges, so the barcode scans cleanly.
- Remove or cover old labels and barcodes if you reuse cartons. Old barcodes cause misrouting.
- Add "Fragile" and "This Side Up" marks where they apply. They don't guarantee careful handling, but they help.
6. Make the unboxing count
For many online shoppers, the box is the first physical contact with your brand. A one-colour logo printed on the carton or mailer box makes plain kraft look deliberate and professional, and it's affordable at volume. Our guide to custom printed carton boxes explains how it works.
7. Shipping in volume? Palletise your outbound orders
If a courier collects many parcels at once, stacking them on a pallet and wrapping it with stretch film keeps the load together, speeds up pick-up and reduces lost parcels.
Packing checklist
- Box sized to the product plus cushioning, not bigger
- Right box type: mailer for presentation, RSC for bulk and weight
- Fragile items cushioned on all six sides
- Gaps filled. The box passes the shake test
- Sealed top and bottom with the H-tape pattern
- One clear label on a flat face, old labels removed
Buying cartons, bubble wrap, void fill and tape from different suppliers costs time and delivery fees. We supply the full e-commerce packing set from our Selangor plants on one order. See packaging for e-commerce businesses.