Shipping products safely is essential for customer satisfaction, brand protection, and cost control. However, many businesses, particularly smaller or newer ones, make packaging mistakes that result in shipping damage.
This guide highlights the most common packaging mistakes that cause product damage in transit. You will learn the root causes of these issues and get clear, practical recommendations to correct them. Start improving your packaging process today—here’s why it matters.
Why Proper Packaging Matters in Transit
Packaging serves as your product’s frontline defense during shipping. It protects against hazards such as:
- Drops and impact shocks
- Vibration and compression
- Moisture and temperature fluctuations
- Rough handling during transportation
Poor packaging leads to damaged products, returns, bad reviews, and lost trust. Strong packaging reduces breakage and returns, protects your reputation, and saves money.
1. Using the Wrong Box Size
The Mistake
Choosing a box that's too large or too small raises the risk of movement, crushing, or breakage.
Why It’s a Problem
- Oversized boxes allow products to shift during transit.
- Undersized boxes put pressure on items, increasing the risk of damage.
How to Fix It
- Choose a box that fits your product snugly.
- Allow only enough space for protective padding.
- Consider custom-sized packaging solutions to minimise empty space.
2. Insufficient Cushioning and Void Fill
The Mistake
It's common to use too little bubble wrap, foam, or paper. Compare cushioning costs to your product's value to determine where additional protection is needed.
- Lightweight Products: Use air pillows to keep packaging light and cost-effective.
- Temperature-Sensitive Products: Opt for foam inserts to provide insulation and maintain temperature.
- High-Value or Fragile Items: Choose bubble wrap and molded pulp for maximum protection.
Ensure products stay in place when you shake the box. Add extra cushioning for fragile or valuable items.
3. Ignoring Product Fragility
The Mistake
Treating all items the same, regardless of their fragility, makes packaging less effective.
Examples
- Shipping glass bottles without protective inserts
- Packing electronics without anti-static protection
Smart Packaging Tips
Add icons to text labels on fragile items to help couriers quickly identify handling requirements. For example, use a wine glass for fragile items, an umbrella for moisture-sensitive goods, or a thermometer for temperature-sensitive products.
- Clearly label fragile items.
- Use double-boxing for breakable goods.
- Apply shock-absorbing or impact-resistant packaging materials.
4. Using Weak or Low-Quality Packaging Materials
The Mistake
Using thin cardboard, weak tape, or poor materials makes shipments less secure. Choose corrugated boxes with the correct Edge Crush Test (ECT) rating. Recycled corrugated boxes suit eco-friendly customers.
- Tape failing during transport
- Increased risk of tampering or theft
How to Improve
- Choose durable corrugated boxes with the correct ECT rating.
- Use high-strength packing tape.
- Reinforce seams, edges, and corners where needed.
5. Poor Sealing and Closure
The Mistake
If you do not seal packages properly or use enough tape, they may open and contents may be lost or stolen.
- Exposure to dust, dirt, or moisture
- Loss or theft of contents
Solution
- Use the H-taping method to secure the top and bottom seams.
- Apply strong adhesive tape or strapping.
- Avoid using weak household tape for shipping.
6. Not Protecting Against Moisture and Weather
The Mistake
Products face serious risks if not protected from weather, humidity, or temperature swings during shipping.
Products at Risk
- Paper-based items
- Electronics
- Food and pharmaceutical products
Prevention Tips
- Use waterproof liners or protective plastic wrapping.
- Include desiccant packets to control moisture.
- Ensure packages are properly sealed to prevent leaks.
7. Overpacking or Underpacking Products
Overpacking Issues
- Higher shipping costs
- Excess material waste
- Increased environmental impact
Underpacking Issues
- Insufficient protection
- Higher chance of breakage
Best Practice
Balance protection and package size by using enough padding to keep items safe without excess material.
8. Poor Weight Distribution Inside Packages
The Mistake
Putting heavy items in the wrong place or stacking them badly.
Consequences
- Package tipping
- Internal crushing
- Product distortion
Fix
- Place heavier items at the bottom.
- Distribute weight evenly throughout the package.
- Use internal dividers when packing multiple items.
9. Skipping Packaging Drop and Stress Testing
The Mistake
Relying on untested packaging is risky—without drop and stress tests, there’s no guarantee your packaging will withstand real shipping conditions.
Why Testing Matters
- Drops and impacts
- Conveyor belt handling
- Stacking under heavy loads
Recommended Action
- Conduct drop and compression tests following ASTM or ISTA standards.
- Simulate real shipping conditions.
- Improve packaging based on test results.
10. Not Labeling Packages Correctly
The Mistake
Not using the right handling labels on packages.
Potential Issues
- Improper handling by couriers
- Incorrect stacking
- Delays or shipping errors
Labeling Tips
- Use labels like “Fragile,” “This Side Up,” and “Handle With Care.”
- Ensure shipping labels are clear, durable, and water-resistant.
Quick Checklist to Prevent Packaging Damage
- ✅ Correct box size
- ✅ Adequate cushioning and void fill
- ✅ Strong packaging materials
- ✅ Secure sealing and taping
- ✅ Moisture protection
- ✅ Even weight distribution
- ✅ Fragile labels where required
- ✅ Packaging tested for transit
How Better Packaging Reduces Returns: A Practical Example
Before: Ceramic mugs shipped in oversized boxes with minimal padding resulted in a 30% breakage rate.
After Improvement:
- Snug-fitting box
- Bubble wrap and cardboard inserts
- Double-sealed tape
Result: Breakage dropped to less than 3%, meaning fewer refunds, lower losses, and happier customers.
Conclusion: Protect Your Products with Smarter Packaging
Packaging mistakes can lead to damage, loss, unhappy customers, and harm to your brand. Most of these problems can be fixed by using better materials, methods, and testing.
By selecting the right box, adding enough cushioning, sealing packages well, and testing packaging, you can reduce shipping damage and improve reliability.
Call to Action: Improve Your Packaging with Packing Solution
Want to reduce product damage and improve your packaging?
Packing Solution UK offers expert advice, quality materials, and custom solutions. Try our free 10-minute packaging audit to improve efficiency and save money. Contact us today to book your audit and discover better, safer, and more affordable packaging.
