Seven Packaging Decisions That Lower Shipping Costs

Dimensional weight is the real cost

Carriers charge on dimensional weight — the greater of actual weight and volumetric weight — so empty space in a box is literally taxed. A stock box padded with void fill can cost more to ship than the product inside it. Right-sizing is the highest-ROI decision in eCommerce packaging.

Seven changes that cut parcel spend

• Right-size the box to the product’s real footprint
• Remove void fill by die-cutting to exact interior dimensions
• Add an insert instead of a larger box to protect product
• Print inside the box instead of adding a separate insert card
• Choose E-flute over B-flute when protection allows
• Gang multiple SKUs on one run to share setup cost
• Reorder at volume once demand is steady — tooling is stored free

Where the savings compound

A 15% reduction in parcel size across thousands of orders compounds into real money. Combined with fewer damage replacements from fitted inserts, right-sized custom packaging routinely lowers total shipping spend by double digits — often more than the per-unit cost of going custom.