Packaging Mistakes That Cost Businesses Money and How to Avoid Them

Posted by Packaging Midlands
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Oct 8, 2025
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Have you ever opened a parcel to discover damaged items inside? The situation then, appears to be extremely frustrating; the company spent significant time on packaging, and the customer eagerly awaited the parcel's arrival, only to find it damaged and useless. This situation raises doubts about the brand in the customer's mind, which can lead to a significant loss of customers when such items are delivered. Your products may be great, but if they're not packed properly, it can lead to disaster.

It therefore becomes extremely important to guarantee that the packaging of all your items is of excellent quality. The packaging significantly contributes to the optimal delivery of your items and the preservation of your brand's reputation. There are a few important things that business owners must pay attention to, which will help them get their stuff delivered to different locations in the best possible manner.

1. Using the wrong-sized box

People often overlook the importance of using the correct box size and frequently choose boxes that are only "close enough" in size. However, these are often the worst decisions to make when shipping certain items, particularly the fragile ones. In a number of global packages that are delivered daily, box sizing errors are one of the most frequent causes of product damage and wasted shipping costs. The shipping company must understand that there is a huge difference between the accurately sized box and the almost right-sized box. Strive for accuracy here and get boxes that are exactly the right size for the items you are shipping. Most often, items are shipped in boxes, which are:

  • If the box is too large, the extra space allows items to move around, increasing the risk of breakage.
  • Too small: You risk bulging seams or crushed edges.

2. Not Using Enough Cushioning

Shake, rattle and break. This is what happens to items that are not packed properly. And always keep in mind that merely shipping the items in the cardboard boxes of the right size is not everything. In the case of shipping items that are especially fragile in nature, it is best if they are wrapped in proper cushioning packaging materials, such as small bubble wrap rolls of different sizes. Ensuring proper cushioning will absorb shock and prevent damage to the items during transit. This process is a crucial step when shipping items, and it matters a lot because:

  • Insufficient padding means impact damage.
  • Customers receive cracked, chipped, or scuffed items.
  • Replacement shipments eat into profit margins.

3. Choosing Weak Tape

So the right boxes are chosen, followed by the right cushioning material – the combination proves to be of excellent strength and ensures that the items placed inside do not get damaged when they are shipped. But is this really enough? Sealing the box is a crucial step that requires meticulous attention. You can easily choose a high-quality strong tape for sealing the boxes to ensure that the items do not spill out during transit if the tapes are weak. Always go for the stronger tapes and ensure that they are properly packed when the items are placed under them.

Common signs of weak tape:

  • Boxes pop open in transit.
  • Tape loses stickiness on dusty or recycled cardboard.
  • Extra layers are needed to keep boxes sealed — wasting time and money.

4. Overpacking or underpacking

Both overpacking and underpackaging are unsafe ways to pack and ship items to different locations. In both cases, items can be damaged from either insufficient or excessive pressure, which may compromise the integrity of the entire packaging. It is therefore important for you to understand what is the right way to get the packaging and how much packaging is actually required for the item that you are shipping.

  • Overpacking adds unnecessary weight and increases postage costs.
  • Underpacking leads to product damage and replacements.

Summing Up

To sum up, there are several factors to consider when preparing to ship items to various locations. Packaging is the primary consideration. Always ensure that you have invested in the right packaging, and its proper use will help you in getting all your items shipped to various locations without getting damaged. All you need to do is look for good packaging suppliers in the UK and get your packaging supplies delivered from them right at your doorstep and that too at discounted prices in case you happen to buy from the wholesaler. 


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