Your warehouse is buzzing with activity, and your team is hustling to meet shipping deadlines. But suddenly, disaster strikes – a batch of overpacked corrugated boxes splits open during loading, scattering products everywhere and delaying shipments.

Not only does this create chaos, but it also damages your reputation and cuts into your bottom line. Overpacking might seem like a harmless oversight, but it can cost businesses time, money, and customer trust.

Luckily, we can help. Read on to find out how to avoid overpacking corrugated boxes.

Efficient Packing Techniques: Understand Weight Limits

Every corrugated box is designed with a specific weight capacity, and overloading it can compromise its structural integrity, leading to potential damage during shipping or handling.

When boxes fail under pressure, it not only risks the safety of the products inside but also results in additional costs for replacements and lost customer trust.

To prevent box overpacking, familiarize yourself with the manufacturer’s weight recommendations for each type of box you use. Weigh the items you plan to pack and ensure the combined weight, including any packing materials, stays well below the maximum capacity.

Choose the Right Box Size: Corrugated Box Handling Tips

Using a box that is too small often forces packers to cram items together, increasing the likelihood of product damage. A box that is too large may require excessive filler materials, which adds unnecessary weight and increases shipping costs.

To ensure you choose the right box size, evaluate the dimensions and quantity of the items being packed. It’s important to have a range of box sizes available in your inventory to accommodate different product shapes and weights. Consider investing in adjustable or customizable boxes for added versatility. You can ask your corrugated box supplier what they recommend for your needs.

Use Quality Packing Materials

One of the easiest ways to optimize the packaging process is to use high-quality materials.

High-quality packing materials provide adequate protection without adding unnecessary weight or bulk to your corrugated boxes.

Lightweight materials such as:

Air pillows
Packing paper
Foam inserts
Biodegradable packing peanuts

can effectively fill void spaces without adding substantial weight. These options provide cushioning to absorb shocks during transportation, reducing the risk of product damage. Avoid heavy materials like excessive layers of bubble wrap or thick paper, as these can contribute to overpacking and increased shipping costs.

Use Reinforcement Wisely

Over-reliance on reinforcement materials, such as excess tape, straps, and shrink wrap, can indicate underlying packing issues. Instead of using reinforcement to compensate for improper packing, focus on using it as a supplement to an already solid packaging process.

For heavier shipments, consider using straps or bands to stabilize the load. Ensure these are applied evenly and securely without overtightening, as excessive pressure can damage the box or its contents.

If you frequently ship fragile or high-value items, reinforced corrugated boxes with double or triple walls can offer extra strength and reduce the need for additional materials.

Stop Overpacking Today

With these strategies, you won’t have to worry about overpacking your boxes.

Are you looking for more boxes? Packaging Fulfillment has over thirty years of experience ensuring companies like yours get the packaging you need.