10 packaging mistakes and how to avoid them

In this article, we’ll highlight the top 10 common packaging mistakes that businesses make and provide actionable solutions to avoid them. Proper packaging not only guarantees the safety of your products but also enhances customer satisfaction and boosts brand reputation. We’ll explore key areas where packaging errors can happen, and how to fix them for more effective, cost-efficient packaging.

Packaging is more than just a box, it’s a vital component of your logistics and brand identity. Poor packaging can result in damaged goods, delayed deliveries, and disappointed customers, while well-thought-out packaging helps reduce returns, improves unboxing experiences, and builds customer loyalty. 

Smart packaging decisions don’t just protect your product, they can actually influence what people buy and how they perceive your brand, as explained in this article on packaging in marketing.

Many businesses overlook small details that can lead to costly packaging errors. Here are ten of the most frequent packaging mistakes to avoid:

Using low-quality or inappropriate materials can compromise product safety. For example, fragile items packed in thin cardboard boxes are prone to damage. To prevent this, use durable, purpose-fit materials like robust cardboard boxes or protective and void fill solutions that offer cushioning and strength.

Oversized packaging increases shipping costs and allows excessive product movement, while undersized packaging can crush or damage items. Choosing the right-sized packaging helps optimise space and ensure product stability. Explore size options through tailored postal packaging solutions to match your needs.

Overpacking leads to unnecessary material use and higher postage fees, while underpacking puts products at risk. The key is to find a balance by using just enough filler and protection to keep the product safe during transit.

Incorrect or missing labels can cause delays, misdeliveries, or compliance issues. Make sure your packages include accurate shipping labels, barcodes, and handling instructions. Implement checks to verify that all information is correct before dispatch.

Packaging is a powerful branding tool. Businesses that ship plain, generic boxes miss the chance to create a memorable unboxing experience. Incorporate brand colors, messaging, and logos on your packaging to make a lasting impression.

Today’s consumers, especially in e-commerce, value the unboxing experience. Unattractive or difficult-to-open packaging can lead to negative reviews. Consider the future of packaging trends that focus on both sustainability and aesthetics to create a positive impact.

In an increasingly eco-conscious world, using non-recyclable or excessive packaging can harm your brand. Switching to sustainable materials not only supports the environment but also resonates with modern consumers.

Without real-world testing, it’s hard to know how your packaging holds up. Test packages under different conditions to identify weaknesses before launching them at scale.

Using different packaging styles or qualities for similar products creates a disjointed brand image. Develop a cohesive packaging strategy that reflects your brand’s values across all product lines. Get inspired by these e-commerce packaging strategies designed for consistency and impact.

Employees unfamiliar with proper packing techniques may cause accidental damage or delays. Provide ongoing training and guidelines to ensure your team knows how to pack products correctly and efficiently.

Different products have different needs. Fragile items require strong cushioning, electronics need anti-static protection, and apparel benefits from lightweight, branded envelopes. Consider using a mix of cardboard, postal, and protective packaging to suit your product range, ensuring both safety and presentation are covered.

To avoid the packaging errors mentioned above:

-Train your team regularly on packaging best practices.
-Audit your packaging process to identify inefficiencies.
-Stay informed about industry trends and the future of packaging.
-Choose trusted suppliers with specialist packaging solutions like those offered by DS Smith ePack.

By addressing these issues proactively, businesses can save money, improve customer satisfaction, and strengthen their brand image, all while reducing waste and shipping risks.