As an ecommerce business grows, so does the number of parcels leaving the warehouse each day. That is usually a welcome sign, but increased order volumes can also make packaging problems much more noticeable. Even a relatively small percentage of damaged deliveries can lead to mounting replacement costs, extra customer service enquiries and disappointed shoppers.
Reducing product damage does not necessarily mean using more packaging. Instead, growing businesses can focus on choosing suitable materials, improving packing processes and identifying where damage is most likely to occur.
Choose Packaging That Matches the Product
A common mistake is using the same type of packaging for a wide range of products. A sturdy book has very different requirements from a ceramic mug, glass bottle or delicate electronic item.
The outer box should be strong enough to withstand handling while remaining appropriately sized for its contents. A box that is much too large leaves room for products to move around, while an overly tight box may provide insufficient space for protective materials.
Businesses should consider product weight, shape and fragility when deciding how each item should be packed.
Prevent Movement Inside the Parcel
Movement is one of the biggest concerns during delivery. Parcels may be stacked, turned and handled numerous times before reaching the customer, so products need to remain secure inside their boxes.
Protective materials can help cushion items and fill empty spaces. Fragile products may benefit from being individually wrapped using materials such as Priory Direct bubble wrap before being placed inside the shipping box. Additional void fill can then be used where necessary to stop the contents shifting during transit.
For orders containing several items, separating products can also prevent them from knocking against one another.
Standardise the Packing Process
As order numbers increase, relying on individual judgement for every parcel can create inconsistencies. One employee might use plenty of protective material while another uses too little.
Clear packing guidelines can help solve this problem. Ecommerce businesses can create simple instructions for different product categories, explaining which box size, protective materials and sealing method should be used.
This makes training new employees easier while helping established teams work efficiently during particularly busy periods.
Test Packaging Before Scaling Up
Packaging that appears secure on a packing bench may behave differently once it enters a delivery network. Businesses introducing new products or packaging formats should therefore test them before sending large volumes to customers.
Simple checks can reveal potential weaknesses. Does the product move when the box is gently shaken? Are fragile areas adequately protected? Could pressure from other parcels damage the contents?
Businesses can also monitor returns and customer complaints to identify products that experience damage more frequently than others.
Make Sure Parcels Are Properly Sealed
Protecting the contents is only part of the process. The outer package also needs to remain closed throughout its journey.
Using suitable packing tape and applying it securely along vulnerable seams can reduce the risk of boxes opening accidentally. Heavier parcels may require stronger boxes or additional reinforcement.
Learn From Every Damaged Delivery
Some damage may still occur, particularly as shipping volumes increase. What matters is how the business responds.
Recording the product involved, type of damage and packaging used can reveal useful patterns over time. If one item repeatedly arrives broken, for example, its packaging method may need to be redesigned.
By treating packaging as an evolving part of fulfilment rather than a one-off decision, growing ecommerce businesses can reduce unnecessary damage, control replacement costs and give customers a more reliable delivery experience.
