Smart Packaging, Fewer Returns: How to Protect Products in Transit

Mailing boxes
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Do you own or manage an eCommerce brand? It can be a one-way ticket to success, with financial freedom and independence awaiting. However, there is a great deal to manage, including advertising and marketing, customer service, accounting, and, in particular, packaging and handling. This article will demonstrate to eCommerce brands how improved packaging can reduce damage, returns, and customer complaints. By the end, you’ll be an expert on all things packaging, including self-seal mailing boxes, which will lead to reduced refunds and return rates, more satisfied customers, and a decrease in complaints. So, if you’re interested in this topic, continue reading to learn more. 

The True Cost of Damaged Deliveries and Returns 

You probably already know that damaged deliveries and returned items cost you money. For one, you’re out of pocket for the item’s profit because you need to replace it. You don’t make a profit on damaged items, as the onus is on you to ship them with adequate protection. Therefore, the major cost is in replacing the stock and shipping it to the disgruntled customer free of charge, which is considered best business practice. 

However, the true cost of damaged deliveries and returns is the loss of customer goodwill and poor reviews. These will cost you so much more in the long run. You won’t likely see a return sale from a customer who has received a damaged item. They will definitely think twice before buying from you again. Secondly, if they leave a poor review, it can be incredibly damaging to your brand. Reviews and customer satisfaction are key to any eCommerce business, and if you have a string of poor reviews due to damaged goods in transit, then new buyers will be wary of purchasing from you. They will worry that their goods will also arrive damaged. As you can see, the true cost of damaged deliveries and returns extends far beyond the cost of replacing the damaged stock. 

The Main Causes of Transit Damage

There are several primary causes of transit damage. The first and foremost is inadequate or poor packaging. Items that are poorly packaged, with insufficient boxes, void fill and tape, are much more likely to get damaged in transit. Lucky for you, as an eCommerce business owner, you can mitigate this on your end; more on this below.

Another major cause of transit damage is carrier mishandling. At times, the postal or courier service may be rough with parcels, which can cause damage. Other causes of damage include warehouse damage, such as when a forklift fork pierces a box or pallet, causing damage to the parcel and its contents. Water damage is also possible if the package is ever left exposed to the elements. This can occur during delivery, when a parcel is left in an insecure location and is exposed to the elements, such as rain. 

Another common cause of damage is box flaps popping open, exposing the contents to the elements. Seams can also split when boxes are packed incorrectly or handled roughly during transit. Corners may get crushed if boxes are stacked too high or compressed under heavier loads. In some cases, sharp or angular products can even pierce through the packaging. All of these problems can be mitigated with proper packaging techniques.

Smart Packaging
Image by freepik

Matching Packaging to Product Type

You should always match your packaging to the product type, as different types, sizes, and shapes of products are packaged with varying strategies. For instance, if you are shipping square or rectangular items, you may want to use corner protectors to ensure the item is even more protected during its journey in transit. For round items, such as plates or bowls, you’ll need adequate void fill and protection, which materials like corrugated cardboard or bubble wrap can provide. Oddly shaped items require packaging that is correct for safe transit, using a combination of adequate void fill and tape to secure the item. 

Simple Packing Best Practices to Reduce Breakages

Next, we’ll cover the basics of taping a box, preparing it for shipping. Using a special tape gun or a roll of sticky tape, you should seal the box from the top and then run the tape across the top to close the two sides of the lid. Next, tape it directly across the box as well, so it is nice and secure. You will want to ensure the box is fully sealed and taped securely so that it won’t pop open during transit. 

One method of taping boxes is called the H-tape method. This is a sealing method that creates the letter “H” using tape across the top and bottom of a box for maximum security. It involves sealing the main centre seam of the box with one strip of tape and then adding two more strips perpendicular to the first, one along each side edge, to form the “H” letter. This reinforces all vulnerable areas of a box, helping to prevent the box from opening during transit, especially for heavier loads. Using an adequately sized box is also best practice here. 

Part of the art of packing a product for shipping in your eCommerce business involves successful void filling, which is the term used to describe filling the voids or empty areas of the shipping box. You can do this using bubble wrap, environmentally friendly paper, cardboard wrapping, or even foam peanuts. Encase the item in the void fill material and use tape to seal it up. The idea is to protect the item in case the box gets thrown, dropped, or otherwise moved roughly during transit. You also need to ensure that the box is the right size, neither too small nor too large for the item being sent. You’ll want to block and brace the item so it can’t move and protect the contents. 

A Shipping Summary

This helpful article covers smart packaging for eCommerce businesses to minimize returns and refunds. We’ve detailed the true cost of returns and refunds, the major causes of transport damage, and how to match packaging to product size and type. Finally, we covered some savvy packaging techniques to ensure that you’re protecting products for their journey.


The content published on this website is for informational purposes only and does not constitute legal, health or other professional advice.


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