A broken mug or a soaked parcel costs more than the item inside. It costs a refund, a second shipment and sometimes a lost customer. This guide covers:

• the packaging materials an online store needs
• how to choose between boxes and mailers
• how to protect fragile items
• how box size affects what you pay to ship

Quick answer

Most e-commerce sellers need six core materials:

1. Sturdy corrugated boxes in a few sizes, for anything that can break or be crushed.
2. Mailers (poly or paper) for soft, unbreakable items such as clothing.
3. Cushioning and void fill, such as bubble wrap, kraft paper or air pillows, so nothing moves inside the box.
4. Strong packing tape, at least 2 inches (about 5cm) wide.
5. Shipping labels and paperwork, including customs forms for international orders.
6. A scale and tape measure, because carriers charge by size as well as weight.

Choose the smallest box that still leaves room for cushioning on every side, then shake-test every parcel before sealing it.

Why packaging choices matter

Packaging has three jobs: protect the product, control shipping costs and shape what the customer thinks when they open it.

Those jobs sometimes pull against each other. More padding protects better but can push you into a bigger, pricier box. Branded boxes look great but cost more than plain ones. The checklist below helps you balance protection, cost and presentation for your own products.

The e-commerce packaging materials checklist

1. Shipping boxes

Use them for: fragile, heavy, rigid or high-value items.

Look for corrugated cardboard. This is cardboard with a wavy inner layer sandwiched between flat sheets, which makes it much stronger than the thin paperboard used for cereal boxes. Single-wall boxes suit most everyday goods. Double-wall boxes are better for heavy or fragile items.

Practical tips:

• Stock three to five box sizes that fit your best-selling products, rather than one size for everything.
• Leave about 2 inches (5cm) of space around a fragile item for cushioning.
• Reused boxes are fine if they are rigid, dry and undamaged. Remove or fully cover old labels and barcodes so the parcel can’t be misrouted.

2. Mailers and envelopes

Use them for: clothing, textiles, soft accessories and other items that can’t break.

• Poly mailers are lightweight plastic envelopes. They resist water, take up little storage space and weigh far less than a box.
• Paper mailers are easier for many customers to recycle at home, but are usually less water-resistant.
• Padded or bubble mailers add a thin cushion for small, slightly delicate items such as jewellery or phone cases.

Never put glass, ceramics or electronics in a mailer, however much bubble wrap you add. A soft envelope can’t protect against crushing.

3. Cushioning and void fill

These terms are often used together, but they do different jobs:

• Cushioning wraps the item to absorb shocks.
• Void fill fills the empty space so the item can’t shift.

Avoid relying on newspaper, towels or clothing as your only cushioning. They compress too easily, and some carriers specifically list them as unsuitable.

4. Tape and sealing

Use pressure-sensitive plastic tape or water-activated (gummed) paper tape that is at least 2 inches wide. Seal the centre seam on the top and bottom of the box, and tape the edge seams on heavier parcels.

Don’t use string, twine, masking tape or household sticky tape. They can snag in sorting machines or come loose in transit.

5. Labels and documents

Every parcel needs a clear shipping label on the largest flat surface, away from seams. Also consider:

• a packing slip listing the contents
• a duplicate address card inside the box, in case the outer label is damaged
• customs declarations for international orders
• return instructions, if your returns policy allows them

6. Tools that save money

• A shipping scale, so you never under-declare weight and get billed an adjustment later.
• A tape measure, because box dimensions affect price (see below).
• A tape dispenser, which is faster and gives cleaner seals than tearing by hand.

7. Optional extras

These are worth considering once the basics are covered:

• branded boxes, tissue paper or stickers
• thank-you cards
• insulated liners and gel packs for temperature-sensitive goods
• tamper-evident seals for high-value or consumable products

How to package an order, step by step

The USPS guide to preparing packages sets out simple principles that apply to most carriers. In practice, the routine looks like this:

1. Choose the box. Pick one with room for cushioning on all sides, but no more.
2. Wrap the item. Wrap each item separately. Fill hollow items, such as vases or mugs, with paper too.
3. Add a base layer. Put cushioning on the bottom of the box before the item goes in.
4. Centre the item. Keep it away from the walls and corners, where impacts are hardest.
5. Fill the gaps. Add void fill around the sides and on top until nothing can move.
6. Shake-test it. Close the flaps and shake gently. If you hear or feel movement, add more fill.
7. Seal it. Tape the centre seams on the top and bottom with wide packing tape.
8. Label it. Fix the shipping label flat on top, plus customs forms if needed.

Packing fragile items

Fragile items need protection at two levels: around the item, and between the item and the outside world.

Use the box-in-a-box method for very fragile goods

Double boxing means packing the wrapped item snugly in one box, then placing that box inside a larger outer box with cushioning between them. UPS’s packaging guidance suggests an outer box about 6 inches (15cm) larger than the inner box in each dimension, with around 3 inches (7.5cm) of cushioning between the two.

It adds cost and weight, so many sellers save it for glass, ceramics and antiques. A single box can work for sturdier items if they are well wrapped and centred with enough padding.

Does writing “fragile” on the box help?

It may help a person handling the parcel, but most parcels are sorted by machines that can’t read it. Treat a “fragile” label as a note, not as protection. Your packing has to protect the item on its own.

Some carriers sell a paid special-handling service for fragile goods. That can be worthwhile for unusual or very valuable items, but it won’t make up for poor packing.

How packaging affects your shipping costs

Carriers price parcels by dimensional weight (also called DIM weight) as well as actual weight.

Dimensional weight is a calculated weight based on the space a box takes up. You multiply length × width × height and divide by a number set by the carrier, called the divisor. If the result is higher than the parcel’s real weight, you pay the higher figure.

This rule recently became stricter in the US. From 12 July 2026, USPS:

• lowered its divisor from 166 to 139, in line with the figure UPS and FedEx commonly use
• began rounding each measurement up to the next whole inch before calculating

USPS applies dimensional pricing to parcels larger than 1 cubic foot (1,728 cubic inches).

Example: a 16 × 14 × 10-inch box holding a 3lb product has a volume of 2,240 cubic inches. Dividing by 139 gives 16.1, which rounds up to 17lb. You would pay for 17lb, not 3lb.

Ways to keep costs down:

• Use the smallest box that still allows proper cushioning.
• Use mailers instead of boxes for soft, unbreakable items.
• Measure every box and enter exact dimensions when you buy a label. Guessed sizes often lead to adjustment charges later.
• Choose light void fill such as air pillows or loosely crumpled paper rather than heavy materials.

Divisors and thresholds vary by carrier, country and service. Check your carrier’s current rules before relying on any figure.

Choosing eco-friendly packaging

Sustainable packaging can mean several different things, and they are not equally useful everywhere:

• Recyclable: materials such as cardboard and paper that most household recycling accepts.
• Recycled content: packaging made partly from material that has already been recycled.
• Compostable: designed to break down in composting conditions. Some types only break down in industrial facilities, not home compost.
• Reusable: sturdy mailers or boxes that customers can use again or send back.

A few honest trade-offs:

• Paper-based void fill is usually easier for customers to dispose of than plastic.
• Compostable mailers often cost more, and their benefit depends on whether customers can actually compost them.
• Right-sizing your boxes reduces both waste and shipping costs, so it is often the simplest sustainable step.

Be careful with claims printed on packaging. Only label materials “recyclable” or “compostable” when they are, and tell customers how to dispose of them. Our Business & Finance articles cover more practical topics for running a small business.

Branding: when it is worth the cost

Branded packaging can make an order feel more personal and help customers remember you. It costs more, though, and it works best once your basic protection and costs are under control.

Low-cost ways to add a brand touch:

• a logo sticker on a plain box or mailer
• branded tape
• a printed thank-you card or care instructions
• tissue paper in your brand colour

Custom-printed boxes usually come with minimum order quantities. Wait until your box sizes and sales volume are stable before ordering them.

International shipping and returns

International orders

Cross-border parcels travel further and are handled more often, so pack them a little more robustly. Every international parcel also needs accurate customs paperwork. That usually means a clear description of the contents, the value and the quantity. Rules on restricted items, labelling and documents differ by country and carrier, so check them before you sell into a new market.

Returns

Packaging that is easy to reuse makes returns simpler. Options include:

• resealable mailers with a second adhesive strip
• boxes that open without being torn apart
• clear return instructions inside the parcel, if your policy allows returns

Keep improving with a simple review routine

Track damaged-in-transit claims by product and by packaging type. If one product keeps arriving broken, change how you pack it before changing carriers. Customer reviews and messages that mention packaging are also worth noting. Comments about too much plastic or boxes that are hard to open can point to easy improvements.

For more practical advice on running a small business, browse our Business guides.

Final thoughts

Good packaging doesn’t have to be expensive. Start with a few well-chosen box sizes, mailers for soft goods, reliable cushioning and strong tape. Then pack every order so nothing can move. Review your damage claims and shipping bills every few months, and adjust your materials as your products and customers change.