Packaging sits between two costs. Too little, and products arrive broken, which means a return, a refund and sometimes a bad rating. Too much, and the parcel is bigger and heavier than it needs to be, which shows up in shipping charges on every single order.
The good news is that the same habits fix both.
Size the box to the product
Shipping is charged on the higher of the actual weight and the volumetric weight, which is worked out from the box's dimensions. A large box around a small product can cost more to ship than the product's weight would suggest. Our guide to volumetric weight explains the calculation.
So the first rule is a box that fits: a few centimetres of space on each side for padding, and no more.
- Keep three or four standard box sizes that cover most of your products, rather than dozens.
- Match each SKU to its box once and write it down, so every packer uses the same one.
- For flat, soft products like clothing, a poly mailer is often lighter and smaller than any box.
Fill the gaps
A product that can move inside the box will hit the walls when the parcel is dropped or stacked. Fill the empty space so it cannot shift.
- Air pillows and bubble wrap are light and protect well.
- Crumpled kraft paper is cheap and works for most items.
- Avoid loose fillers that spill out when the buyer opens the box.
Give the box a gentle shake when it is closed. If you hear or feel the product move, add more filler.
Protect what breaks
Glass, ceramics, electronics and anything with a screen need more care:
- Wrap the item itself first, then pack it in the box with filler around it.
- Keep fragile items away from the box walls, especially the corners.
- Use a double-walled box for heavy or fragile products.
- Pack liquids in a sealed bag inside the box, with the cap taped.
Seal it properly
A box that opens in transit loses its contents or invites tampering.
- Use good packing tape and seal every seam, top and bottom, in an H pattern.
- For valuable products, tamper-evident tape shows the buyer the box has not been opened.
- Do not over-wrap the box in tape; it adds weight and makes the parcel hard to open.
Put the label where it belongs
- Stick the label flat on the largest face, on top, away from seams and edges.
- Do not let tape run over the barcode. Shiny tape can stop a scanner reading it.
- Remove or cover any old labels or barcodes on a reused box.
Weigh and measure the packed parcel
The weight and dimensions you send to the marketplace should be the packed parcel's, box and filler included. Weigh a few packed samples of each SKU on a proper scale, measure the box, and save the numbers. Sending the product's own weight instead is one of the most common causes of weight disputes and extra charges.
Record evidence for valuable orders
For high-value items, a short video or a couple of photos of the product going into the box and the box being sealed, with the label visible, can help if a buyer claims the parcel arrived empty or damaged. Keep them until the return window has passed.
Keeping the numbers in one place
The Sellerio Seller Toolkit, a free Chrome extension for Amazon, Flipkart and Meesho, keeps the packed weight and box size for each SKU in My SKU Setup, with a separate one for each quantity you ship together, and fills them in on Amazon Easy Ship and Flipkart as it processes each order1.
Add to Chrome — freeAmazon, Flipkart & Meesho · Free for everyone · No API key or password
It runs in Chrome on a computer. On a phone, send yourself the link.
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