Shipping damage is more than an inconvenience—it leads to wasted products, unhappy customers, and added costs. Many shipment issues stem from preventable packaging mistakes. Understanding what goes wrong most often helps ensure your items arrive safely and intact.
Using the Wrong Box Size or Strength
One of the most common mistakes is choosing a box that’s too large, too small, or not strong enough. Oversized boxes allow items to shift during transit, while undersized boxes increase pressure on seams and corners. Lightweight boxes may collapse under stacking weight.
Selecting the correct corrugated box size and strength for your product is essential for proper protection.
Skipping Proper Cushioning and Void Fill
Boxes alone do not prevent damage—internal cushioning does. Failing to use padding such as packing paper, bubble wrap, or void fill allows items to move freely inside the box. This movement increases the risk of impact damage during shipping.
Proper cushioning keeps items centered and absorbs shock, especially for fragile or irregularly shaped products.
Overloading Boxes Beyond Capacity
Overpacking a box can weaken its structure and cause it to burst during handling. Every box has a weight limit, and exceeding it compromises durability. Heavy items should be distributed across multiple boxes or packed in reinforced corrugated packaging designed for higher loads.
Using the right box for heavier shipments helps maintain structural integrity throughout transit.
Poor Sealing and Taping Techniques
Inadequate taping is another frequent issue. Using low-quality tape or sealing only the center seam leaves boxes vulnerable to opening. Applying tape along all seams using the proper “H-taping” method ensures boxes stay secure during handling and transport.
Reusing Worn or Damaged Boxes
Reusing boxes may seem cost-effective, but worn corners, weakened flaps, and old creases reduce protection. Previously used boxes are more likely to fail, especially during long-distance shipping or stacking.
Choosing new, sturdy boxes helps reduce the risk of unexpected breakage.
Pack Smarter to Ship With Confidence
Avoiding these common packaging mistakes protects your products and your reputation. With the right boxes, materials, and packing techniques, shipments arrive safer, customers stay satisfied, and replacement costs stay low. Contact us today to get a free quote on your next shipping.