Reducing packaging material may appear to lower the cost of each shipment. However, those savings can disappear when the packaging doesn’t provide adequate protection.
Damage claims, replacement shipments, returns, repacking, and customer complaints can all increase the total cost of an inadequate packaging design. The lowest material cost does not always produce the lowest overall packaging cost.
The following signs may indicate that current packaging choices are creating more expensive than they prevent.
A gradual increase in damaged shipments can be easy to attribute to carriers, warehouse handling, or isolated product issues. However, packaging changes should also be reviewed.
Reduced board strength, cushioning, insert thickness, or box dimensions may affect how a product performs during transportation. Changing suppliers or replacing a custom structure with a stock box can also alter the level of protection.
Compare the timing of packaging changes with damage claims and return records. Look for patterns by product, box size, shipping route, or damage type. This can help determine whether the packaging specification requires further review.
Using one box for several products may simplify packaging inventory. It can also create large internal gaps around smaller items.
Warehouse teams may compensate by adding paper, foam, or another form of void fill. This increases material use and adds another step to the packing process. If the fill does not secure the product consistently, the item may still move inside the box.
A small group of custom box sizes can offer a practical alternative. The goal is to balance packaging inventory with each product group’s dimensions and protection needs.
Customer feedback can reveal packaging problems that internal reporting misses. Comments about crushed cartons, damaged products, excessive void fill, or loose items deserve attention.
The condition of the package can affect the customer’s first physical interaction with a product. A damaged or poorly fitted box may create concern before the product is inspected.
Review packaging-related comments alongside return reasons and damage reports. Repeated complaints about similar issues may indicate a structural problem rather than an isolated shipping event.
Packaging should also support the intended presentation. Custom inserts, fitted cartons, and appropriate protective materials can help keep products secure and organized when the package is opened.
Changing a box can affect more than material costs. It may also change how much space each packed product occupies.
Parcel shipping charges may consider package dimensions as well as weight. The exact calculation depends on the carrier service and agreement. A larger box can therefore affect shipping costs even when the product remains unchanged.
Compare freight invoices before and after a packaging change. Review high-volume products first, since repeated dimensional differences may be easier to identify across regular shipments.
Packaging dimensions should also be considered for pallet layouts, warehouse storage, and shipping areas. A suitable design must balance space efficiency with product protection.
Packaging performance cannot be evaluated without basic tracking. If damage reports are handled individually, decision makers may not see the combined cost.
Useful records can include:
This information does not need to create a complex reporting process. Consistent records can provide enough visibility to identify repeated problems and prioritize packaging reviews.
Assess protective packaging solutions based on product fit, handling conditions, material use, freight requirements, and damage exposure. Focusing only on box cost can leave higher operational costs unexamined.
The guide to right-sized packaging for Canadian businesses explains how product fit, materials, and handling requirements shape packaging design. This may include a custom corrugated box, foam or fibre inserts, honeycomb support, edge protection, or heavy-duty bulk packaging.
Coleman Containers designs and manufactures custom packaging around specific products and supply chain requirements. Contact Coleman Containers to discuss current damage concerns and review whether the existing packaging provides the right fit and protection.
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