When a customer receives a damaged parcel, the consequences can extend far beyond the cost of replacing the product. Businesses may face returns, refunds, additional shipping expenses, negative reviews and a loss of customer trust. For Australian ecommerce businesses, wholesalers and retailers, effective packaging is an important part of delivering a positive customer experience.
So, why do packages arrive damaged even when they appear to be packed securely? In many cases, the problem starts before the parcel leaves the warehouse. An unsuitable box, insufficient cushioning, poor tape selection or incorrect packing technique can leave products vulnerable during handling and transportation.
The good news is that many common packaging problems can be avoided with the right materials and a consistent packing process.
In this guide, we'll explore eight common packing mistakes businesses should avoid, explain how they can contribute to shipping damage and share practical solutions to help protect products during transit.
Why Do Packages Arrive Damaged?
Packages can be damaged for several reasons, including inadequate cushioning, incorrect carton selection, poor sealing and insufficient protection against movement. Parcels may be handled multiple times as they move through sorting facilities, delivery vehicles and distribution centres. During this process, they can experience impacts, compression, vibration and changes in handling conditions.
Even a product that leaves your warehouse in perfect condition can arrive damaged if its packaging is not suitable for the journey.
Common causes of shipping damage include:
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Products moving around inside boxes.
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Fragile items coming into direct contact with one another.
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Packaging that cannot withstand stacking or compression.
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Cartons opening because of weak or poorly applied tape.
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Sharp edges damaging protective materials.
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Insufficient protection for heavy or irregularly shaped products.
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Incorrect packing methods for delicate items.
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Inadequate final checks before dispatch.
Understanding these problems is the first step towards reducing damaged deliveries and improving your packaging process.
1. Choosing the Wrong Box Size
One of the most common packaging mistakes is using a box that is either too large or too small for the product.
An oversized box leaves excess space around the contents. If that space isn't filled appropriately, the product can shift during transit and collide with the carton walls or other items. A box that is too small may leave insufficient room for cushioning, placing pressure on the product or making the carton difficult to close securely.
How to avoid this mistake
Choose a shipping box that accommodates the product and its protective packaging without leaving excessive empty space.
Before selecting a carton, consider:
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The product's dimensions and weight.
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The space required for protective wrapping.
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Whether the product has fragile corners or protruding parts.
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The strength of the carton needed for the shipment.
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Whether multiple items will be packed together.
Packing tip: Measure the product after accounting for any protective wrapping. The box should provide enough room for cushioning on all sides without allowing unnecessary movement.
Using appropriately sized cardboard shipping boxes can help businesses improve packing efficiency, reduce excess packaging material and provide better protection during delivery.
2. Using Too Little Protective Packaging
A sturdy cardboard box alone may not be enough to protect fragile or delicate products. Without sufficient cushioning, items can be damaged by impacts, vibration or contact with other contents.
Glassware, ceramics, electronics accessories, decorative products and delicate homewares may require additional protection depending on their fragility and shipping conditions.
How to avoid this mistake
Choose protective packaging based on the type of product being shipped.
Bubble wrap is useful for wrapping fragile items and providing cushioning against impacts. Kraft paper can help protect surfaces, separate products and fill empty spaces inside cartons. Other protective materials may be appropriate for products with specific cushioning requirements.
For delicate shipments:
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Wrap fragile products individually where necessary.
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Protect vulnerable corners, edges and protruding parts.
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Place the wrapped products inside a suitable carton.
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Fill remaining gaps with appropriate void-fill material.
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Check that the contents cannot move freely.
Avoid assuming that one thin layer of wrapping will protect every product. The amount and type of cushioning should match the product's needs.
3. Leaving Empty Spaces Inside the Box
Even when a business chooses the correct box size, poor placement of the contents can create empty spaces that allow products to move around.
This is particularly problematic when several items are packed in the same carton. Products can collide with one another, shift towards the edges or put pressure on more delicate contents.
How to avoid this mistake
Use suitable void fill to stabilise the contents of the box.
Void-fill materials occupy unused space and help prevent movement during handling and transportation. Depending on the product, options may include crumpled kraft paper, bubble wrap or other suitable protective packaging.
For example, a business shipping several ceramic mugs could wrap each mug individually, position them with suitable separation and fill the remaining spaces so that the items stay in place.
Before sealing the box, gently move it from side to side. If the contents shift noticeably, reassess the packing arrangement and add suitable protective material.
Remember: Filling gaps is not the same as cushioning a product. Fragile items may need both individual protection and sufficient void fill to reduce movement.
4. Using the Wrong Packing Tape
Packing tape plays an important role in keeping cartons securely closed. However, using an unsuitable tape or applying it incorrectly can cause the box to open during handling.
Tape performance can be affected by the carton surface, dust, temperature, application technique and the weight of the contents. A tape that works well for a lightweight parcel may not be suitable for a heavier carton.
How to avoid this mistake
Select packaging tape according to the carton, load and shipping requirements.
Consider these options:
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Standard carton-sealing tape: Suitable for many everyday packaging applications when matched to the carton and load.
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Reinforced filament tape: Provides reinforcement for suitable bundling and heavy-duty packaging applications.
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Kraft paper tape: A paper-based option for appropriate carton-sealing applications, depending on the adhesive and product specifications.
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Water-activated tape: Uses water to activate its adhesive and can provide a secure carton seal when applied correctly to compatible cartons.
Before applying tape, ensure the carton flaps meet properly and the sealing surfaces are clean and suitable for adhesion. Apply tape evenly and make sure it extends securely across the closure.
For heavier shipments, use a sealing method appropriate to the carton manufacturer's recommendations and the shipment's weight.
5. Packing Multiple Items Without Separating Them
Packing several products into one box can be efficient, but allowing them to touch directly may increase the risk of scratches, chips and breakage.
For example, glass bottles packed together without separation may collide during transit. Similarly, metal components, ceramic items or products with sharp edges can damage neighbouring items.
How to avoid this mistake
Create separation between individual products using suitable wrapping or dividers.
Depending on the items, you can use:
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Bubble wrap around fragile products.
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Kraft paper between items to reduce surface contact.
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Cardboard dividers to separate products within a carton.
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Suitable inserts for bottles or other delicate goods.
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Additional cushioning around vulnerable corners and edges.
If you're shipping a combination of heavy and fragile products, avoid placing heavy items where they can press against delicate ones.
The aim is to keep products separated, supported and protected throughout the journey.
6. Ignoring the Weight and Strength of the Carton
Not all cardboard boxes are designed to carry the same loads. A lightweight carton may be suitable for small, light products but unsuitable for heavy goods or shipments that need to withstand stacking.
Using an inappropriate box can increase the risk of crushing, deformation, torn seams and damage to the contents.
How to avoid this mistake
Match the carton to the weight, dimensions and handling requirements of the shipment.
When selecting a box, consider:
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The total packed weight, including protective materials.
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The product's shape and weight distribution.
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Whether the parcel will be stacked with other cartons.
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The carton specifications and intended application.
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Whether the contents need additional structural support.
Heavy or bulky products may require a stronger carton than lightweight goods. Depending on the application, double-wall corrugated boxes may be worth considering for additional strength compared with suitable single-wall alternatives.
Do not rely on box appearance alone. Check the carton specifications and any applicable weight recommendations before packing.
7. Packing Fragile Items Without a Clear Protection Strategy
Fragile products often need more than a generic wrapping material. Different products have different vulnerabilities, and a packing method that works for one item may not be suitable for another.
For example, a glass ornament may need individual cushioning, while a product with exposed corners may require targeted edge protection. A delicate item packed tightly against the box wall may still be vulnerable to impact.
How to avoid this mistake
Develop a repeatable packing method for products that are frequently shipped.
For fragile goods, consider the following process:
Step 1: Inspect the product. Identify vulnerable areas such as corners, handles, glass surfaces and protruding parts.
Step 2: Select suitable cushioning. Choose protective materials that fit the product's shape and fragility.
Step 3: Wrap the product securely. Ensure vulnerable surfaces are covered without placing excessive pressure on delicate components.
Step 4: Position it inside the carton. Keep sufficient cushioning between the product and the outer walls.
Step 5: Stabilise the contents. Fill empty spaces and separate multiple items where necessary.
Step 6: Check the finished parcel. Confirm that the contents are secure and the box is properly sealed.
Labels such as “Fragile” can help communicate handling requirements, but they should never replace appropriate cushioning and packaging.
8. Skipping the Final Packing Inspection
A parcel may contain the correct products and use suitable packaging, yet still be vulnerable if the final inspection is overlooked.
Loose tape, exposed contents, unfilled gaps or damaged cartons can all create avoidable problems. During busy dispatch periods, these issues may go unnoticed if employees rush through the packing process.
How to avoid this mistake
Introduce a simple pre-dispatch checklist that employees can follow before parcels leave the packing station.
Shipping packaging checklist
- The correct box has been selected for the product.
- Fragile items have suitable protective wrapping.
- Products are separated where necessary.
- Empty spaces have been filled appropriately.
- The carton is not overloaded.
- All flaps are properly closed and sealed.
- Tape is firmly attached across the closure.
- The outer carton is in suitable condition.
- The shipping label and delivery details are correct.
- Any necessary handling labels are visible.
A consistent inspection process can help identify packaging problems before dispatch and reduce the likelihood of avoidable damage.
How to Choose the Right Packaging Materials for Your Business
Choosing the right packaging materials depends on what you sell, how your products are handled and the level of protection required during transit.
Here is a quick guide to common packaging supplies and their uses.
| Packaging material | Common application |
|---|---|
| Cardboard shipping boxes | Outer protection and containment |
| Bubble wrap | Cushioning fragile items |
| Kraft paper | Wrapping, separating products and void filling |
| Reinforced filament tape | Suitable reinforced sealing and bundling applications |
| Carton-sealing tape | Closing and securing shipping cartons |
| Cardboard dividers | Separating products inside a box |
| Fragile tape | Communicating that a parcel contains delicate items |
| Protective packaging materials | Additional cushioning or protection based on product requirements |
The most effective packaging setup often combines several materials rather than relying on one product to do everything.
For example, a fragile ecommerce order may need a suitable cardboard box, individual bubble-wrap protection, kraft paper to fill remaining gaps and reliable carton-sealing tape.
Businesses that ship products regularly should also review their packaging process periodically. Monitoring damage reports, customer feedback and returns can help identify recurring issues and improve packing methods over time.
How Better Packaging Can Improve Customer Experience
Packaging is more than a way to transport goods. It is part of the overall customer experience.
When a parcel arrives in good condition, customers can enjoy their purchase as expected. When products arrive broken, scratched or incomplete, the experience can lead to complaints, returns and additional work for customer service teams.
Improving packaging can help businesses:
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Reduce avoidable product damage.
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Minimise replacement shipments and return handling.
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Improve packing consistency.
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Protect products during storage and transportation.
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Build customer confidence in order fulfilment.
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Make better use of packaging materials.
No packaging method can eliminate every shipping risk. However, choosing suitable materials and following a consistent packing process can help businesses reduce preventable problems.
For Australian ecommerce businesses, wholesalers and retailers, reviewing packaging practices is a practical step towards more reliable order fulfilment.
Frequently Asked Questions
Why do packages arrive damaged during shipping?
Packages may arrive damaged because of inadequate cushioning, unsuitable box sizes, insufficient void fill, weak carton sealing or handling impacts during transportation. Choosing appropriate packaging and securing products properly can help reduce these risks.
What is the best packaging material for fragile items?
The best material depends on the product's size, shape, weight and fragility. Bubble wrap is commonly used for impact cushioning, while suitable inserts, dividers and void-fill materials can provide additional support.
How can I stop products from moving inside shipping boxes?
Wrap products appropriately, choose a suitable box size and fill empty spaces with suitable void-fill material. Before sealing the carton, check that the contents do not move freely.
Is bubble wrap enough to protect fragile products?
Not always. Bubble wrap can provide cushioning, but fragile products may also need a sturdy carton, protection around vulnerable areas and void fill to prevent movement. The complete packaging setup matters.
Does fragile tape prevent shipping damage?
Fragile tape helps communicate that a parcel contains delicate items, but it does not physically cushion the contents. Products still need suitable wrapping, cushioning and secure placement inside the box.
How can businesses reduce packaging costs without increasing damage?
Use appropriately sized cartons, select materials suited to each product, train staff in consistent packing methods and review damage reports. Avoid removing essential cushioning simply to reduce material costs.
Should businesses use stronger boxes for heavy products?
Heavy products may require stronger cartons, depending on their weight, dimensions and shipping conditions. Check carton specifications and use appropriate internal support to protect both the product and the box.
Final Thoughts
Damaged deliveries can create unnecessary costs, disrupt order fulfilment and affect customer satisfaction. Fortunately, many common packaging mistakes can be addressed by improving carton selection, using appropriate protective materials, securing products properly and checking every parcel before dispatch.
From choosing the right box and cushioning fragile items to selecting suitable tape and filling empty spaces, every stage of the packing process contributes to a safer shipment.
The key is to match your packaging to the product, rather than using the same method for every order.
Whether you're shipping fragile homewares, everyday ecommerce products or heavier commercial goods, the right combination of packaging supplies can help protect your products from warehouse to delivery.