Packaging isn’t just about product protection—it directly affects your shipping costs. Improper packaging can trigger dimensional weight fees, result in damaged goods, and lead to unexpected surcharges from carriers like UPS, FedEx, and USPS. For small businesses and e-commerce sellers, avoiding these common errors can help maintain margins and reduce fulfillment headaches.
Here are the top 10 packaging mistakes that drive up shipping rates—and how to fix them.
- Using Oversized Boxes
Carriers use dimensional (DIM) weight pricing to calculate charges based on the size of your package, not just the weight. Using a box that’s too large—even if it’s light—can result in higher shipping fees. Use right-sized packaging tailored to your product to keep costs low.
- Ignoring Flat Rate Opportunities
Services like USPS Priority Mail Flat Rate and UPS Simple Rate allow you to ship for a consistent fee, regardless of weight or zone (up to certain limits). Not using these when appropriate can mean overspending for heavier shipments.
- Underpacking or Overpacking Products
Underpacking leads to product damage, while overpacking increases weight and size. Either mistake results in higher costs—either from returns or additional shipping fees. Optimize internal cushioning with materials like corrugated inserts or air pillows to strike the right balance.
- Not Pre-Weighing and Measuring
Estimating weight and size leads to inaccuracies in rate calculations and may result in carrier adjustments. Always use a postal scale and measuring tape to get precise data before printing labels.
- Neglecting Branded Packaging Efficiency
Custom packaging can improve brand perception, but it often sacrifices efficiency. If your branded boxes are oversized or oddly shaped, carriers may charge more. Work with companies like Packlane or EcoEnclose to create right-sized, sustainable packaging that doesn’t compromise presentation or cost.
- Failing to Label “Fragile” or “Perishable” Correctly
Incorrect or missing labels can lead to damaged items and claims. Labels like “Perishable,” “Fragile,” or “This Side Up” help carriers handle your package appropriately—and reduce the risk of costly refunds.
- Overusing Filler Materials
Heavy fillers like shredded paper or crumpled cardboard add unnecessary weight. Instead, use lighter options like bubble wrap, foam sheets, or recycled air pillows. This helps reduce shipping weight without compromising protection.
- Not Factoring in Return Logistics
Packaging that can’t be resealed or reused adds cost to the return process. Use resealable mailers or easy-close boxes to simplify returns and lower associated shipping costs.
- Ignoring International Packaging Standards
For global shipping, packaging needs to comply with international standards, including documentation pouches and export markings. Failing to do so may result in customs delays or repackaging fees.
- Missing Out on Cashback Opportunities
While packaging strategy is key, payment strategy also matters. Businesses can earn cashback with a FedEx virtual card, get rewards with a UPS virtual card, or earn cashback with a USPS virtual card by purchasing virtual cards through Fluz. This gives you a return on routine shipping expenses without changing your fulfillment systems.
Conclusion
Avoiding these packaging mistakes is one of the easiest ways to reduce shipping costs without compromising quality. By choosing right-sized boxes, verifying measurements, and using efficient internal packaging, you’ll cut unnecessary fees. And when you pair these best practices with cashback tools like Fluz, your shipping spend becomes an investment—not just an expense.
