5 Common Packing Mistakes (and How to Avoid Them)

Most shipping damage comes down to a handful of avoidable mistakes. Here are the five we see most often and how to fix them.

1. Using a box that's too big

An oversized box lets contents shift in transit and costs more thanks to dimensional weight pricing. Choose the smallest box that still leaves room for proper cushioning.

2. Skimping on cushioning

Fragile items need at least two inches of cushioning between the item and every wall of the box, with all gaps filled so nothing moves. Bubble wrap, air pillows, or packing paper all work — the key is no empty space.

3. Under-taping the box

A single strip of tape isn't enough for a packed box. Use the H-tape method — one strip down the center seam and one across each end edge, top and bottom — with tape rated for the box's weight.

4. Reusing a worn-out box

Cardboard loses strength every time it's used. A soft, crushed, or previously soaked box won't protect your contents. Reuse boxes only while they're still rigid and dry, and cover old labels.

5. Choosing the wrong mailer

Soft goods do fine in a poly mailer, but anything fragile or rigid needs a bubble mailer, a rigid mailer, or a box. Matching the packaging to the product is the single easiest way to cut damage.