18 bitesize tips for packing postal orders and eCommerce fulfilment

Whether you ship a few or hundreds of eCommerce and postal orders each day, how you pack them significantly impacts your productivity, shipping protection, and customer satisfaction.

Tips for packing postal orders include using correctly-sized boxes, adding appropriate void fill to prevent products from moving, and sealing them with suitable tape. Avoiding over-packing, under-packing, and not strapping multiple boxes together is also vital.

Due to the importance of getting your goods to your customers in the condition they left your warehouse or fulfilment centre, this guide provides 18 bite-sized tips to ensure you and your packing teams pack items quickly, efficiently and in a manner that prevents damage.

There are many considerations when sourcing postal packaging for eCommerce and mail order. But what about when you already have your packaging and are trying to ensure your staff are packing goods and products correctly?

Well, the 18 postal packing tips you should adhere to (or at least consider) are:

• Choosing an appropriately sized box.
• Using packaging suitable for the products your shipping.
• Ensuring boxes are properly assembled.
• Ensuring boxes are not damaged.
• Fill voids in the parcel to prevent movement and damage.
• Ensuring multiple items are separated.
• Keeping fragile items away from the walls of the outer box.
• Using suitable inserts.
• Specialist packaging materials for electronics.
• Taking extra care for specific products (glass, ceramics etc.)
• Individually packaging items within an outer pack for sets and delicate items.
• Using temperature control inserts for fresh items.
• Ensuring boxes are not under-packed.
• Ensuring boxes are not over-packed.
• Using suitable tape to seal boxes.
• Avoid strapping boxes together.
• Using clear labels for your parcels to arrive at their destination.
• Not forgetting supplementary contents, such as flyers, return labels, etc.

These tips can be divided into several distinct areas: selecting appropriate packaging, inserts and secondary packaging, specialist considerations for specific items, labelling, and general tips.

You should also consider the most appropriate type of packaging for your products. While most items are best sent in corrugated packaging or specialist eCommerce boxes, fabric products such as clothing and apparel can be sent in poly bags. Cardboard tubes are more suitable for rolled products, such as mats and posters. Suitable packaging will improve transport protection and be more cost-effective.

If you are using cardboard boxes, it is vital to ensure that your packing teams assemble them correctly. All tabs and closures should be pushed into place firmly to ensure that the box does not come apart during transportation.

Similarly to ensuring that boxes are assembled correctly, it is also crucial that they are not damaged before despatch. Any tears or rips can grow as the parcel is moved through the courier or postal network. Damp boxes will also have reduced structural strength. Make sure you and your team only use packaging that is in good condition.

If shipping multiple items within a single pack, it is vital to separate them during transport. This can be done by including void fill or specialist items such as divider sets or custom fittings (and even foam for very fragile items). Separating items stops them from damaging each other during normal handling processes.

In addition to preventing movement, you should aim to keep fragile items away from the box’s inner walls. Any forces, for example, if a box is dropped or placed into a stack of other parcels, are transferred straight through the outer material and onto the product (potentially causing damage). Keeping items away from walls using cardboard fittings or even Korrvu prevents this type of damage.

Any inserts and internal packaging materials should be strong enough for the product they protect. For example, bubble wrap only prevents cosmetic damage to large, heavy items. As such, larger items typically require some form of foam packaging or end caps. Try to avoid polystyrene, as it is only effective for a single drop and is poor for sustainability.

As with electronics, fragile items need adequate protection from shock, impact, and vibration. However, you should also consider whether their packaging would allow them to be stored in fulfilment centres, sorting offices, and delivery vehicles.

When packing items that come in sets or are fragile, packing them into individual boxes before placing them into a large box can significantly improve protection. Another option to explore is specialist packing or foam inserts that have specific recesses for individual items.

Fresh produce requires suitable temperature control inserts to prevent spoilage during transit. Chilled packaging includes a range of inserts that can be added to standard corrugated packaging. Also consider whether additional ice packs or similar cooling devices are required.

Conversely, over-packing boxes make them much more likely to burst or split, causing them to lose their contents before they reach your customers. When selecting or specifying a box size, aim for one that is only slightly too large for the products you put into it.

Ensure you seal your packaging well with appropriate tape. Failure to do this can allow the box to open during handling. Insufficient or inadequate taping also makes it easier for potential thieves to open the boxes and take the contents. For heavier-duty shipments, you should tape all joints for a stronger closure and added protection.

Boxes that are trapped together are difficult for couriers to handle and process. Items can also become separated and lost. If shipping multiple items, try to place them into one larger box or, if this is not possible, send the items as separate shipments (labelled appropriately, e.g. 1 of 2, 2 of 2, etc.).

Finally, remember to add supplementary contents, such as flyers, return labels, etc., when packing your postal orders.