What Happens to a Parcel in Transit?
Parcels are scanned, sorted and moved many times. They slide down chutes, ride conveyors, sit in roll cages under other parcels and bounce around in vans. A box needs to survive drops of a metre or so, pressure from parcels stacked on top and the odd knock at a corner. Packing for that journey, not for the packing bench, is the whole idea.
Start With the Right Box
A box that fits the contents closely is the single biggest defence against damage. Too big, and the contents shift and the walls cave in under weight. Too small, and the corners of the product press against the board. Choose the grade for the weight and fragility of the contents.
| Parcel | Box | Board |
|---|---|---|
| Light, sturdy | Mailer or shipping box | E or B flute |
| Moderate weight | Shipping box | B or C flute |
| Heavy or fragile | Shipping box | BC double wall |
| Several breakable items | Shipping box with dividers | B flute or BC with a grid |
How Should Items Be Wrapped?
Wrap each fragile item individually so nothing touches anything else. Paper, bubble wrap and moulded pulp all work; what matters is that every surface is covered and corners are padded. Pack bottles and jars upright, ideally in a divider grid.
- Wrap fragile items one by one
- Pad corners and edges first
- Keep liquids upright and sealed in a bag
- Separate items with dividers or card
How Much Void Fill Do You Need?
Enough that nothing moves when you shake the closed box. Fill the bottom, place the items, then fill the gaps and the top. Crumpled paper, air pillows and shredded card all work. Too little and items shift; packed so tight that the box bulges and the walls lose their strength.
For repeat products, a made-to-fit insert is quicker than loose fill. See cardboard dividers and inserts for the options.
How Do You Tape a Box Properly?
The H pattern stops flaps lifting at the ends, which is where most taped boxes fail. Mailer boxes with tuck lids need only a strip or a seal across the front.
- Use proper parcel tape, about 48 mm wide, not office tape.
- Run one strip along the centre seam of the bottom flaps.
- Run a strip across each end seam, making an H shape.
- Repeat the H on the top once the box is packed.
- Press the tape down firmly along its whole length.
Where Should the Label Go?
On the largest flat face, clear of seams and edges, so scanners can read it. Remove or cover old labels and barcodes on reused boxes; a stray barcode can send a parcel to the wrong place. Add a return address in case the label is damaged.
Do Handling Marks Help?
Fragile and This Way Up marks can help where a parcel is handled by people, but automated sorting ignores them. Treat them as a reminder for the last few people in the chain, not as protection. Good packing does the real work.
The Shake Test
Before sealing the top, close the flaps and give the box a firm shake. If you hear or feel anything moving, add more fill. Then press gently on the top and sides: the box should feel solid, not hollow or bulging. A minute spent on this test saves most breakages.
What About Weather and Damp?
Parcels often wait on a doorstep, in an open van or on a loading bay, and cardboard weakens when it gets wet. You cannot stop a box from ever getting wet, but you can reduce the risk. Put items that must stay dry in a sealed bag inside the box, avoid leaving packed parcels outside before collection, and store flat boxes off the floor in a dry room so they start their journey at full strength.
If a delivery is likely to sit outside, a plain outer carton around a printed box keeps the printed box clean and dry, and it means the box your customer keeps arrives looking new.
Packing Heavy Parcels
Heavy parcels put more strain on the base and the seams, and they are handled more roughly because they are awkward to lift. Use double wall board, tape the base with two H patterns if the load is dense, and keep the weight low and central. Split very heavy orders into two boxes rather than one that is hard to carry.
Packing Several Small Items Together
Mixed parcels fail when small items rattle against larger ones. Put small items in their own small box or bag first, then pack those inner packs into the outer carton with fill around them. It keeps everything together and makes the parcel easier to check on arrival.
Training Whoever Packs Your Parcels
If several people pack orders, write the method down: which box for which product, how much fill, where the tape goes and where the label sits. A one-page guide pinned above the bench keeps parcels consistent, and consistency is what keeps damage rates low week after week.
What Should You Do About Damage?
Keep a note of damaged deliveries and look for a pattern. Crushed boxes point to board that is too light or boxes that are too large. Broken contents with an intact box point to wrapping and fill. Corner damage points to the box size or the grade. Fixing the cause usually costs less than replacing goods.