You probably think a lot about how your packaging looks. But have you thought about how much it’s costing you every single day?
Every oversize box, flimsy filler, or clunky packing step adds up, and not in your favor. Most carriers aren’t going to flag the inefficiencies for you. In fact, they benefit when your packaging costs more and ships less efficiently.
In this post, we’re pulling back the curtain. Our shipping experts are revealing six truths other carriers won’t tell you about packaging efficiency and what you can do to optimize your packaging process, reduce waste, and protect your margins.
1. Oversize Boxes Make Carriers Rich; Right-Sizing Makes You Smart
If you’ve ever shipped a lightweight item in a large box, you’ve probably paid more than you should have and your carrier didn’t stop you. That’s because most major carriers use dimensional (DIM) weight pricing, which means you’re not charged based on the package’s actual weight; you’re charged based on how much space your box takes up.
That “extra air” in every oversize box can be a profit for shippers.
What some carriers won’t tell you is this: Right-sizing your packaging is one of the easiest, most effective ways to reduce shipping costs.
By choosing the smallest possible packaging that still protects your product, you can:
- Avoid inflated DIM charges
- Save on filler materials
- Reduce storage space in your warehouse
- Lower your environmental impact
- Improve the customer experience with cleaner, more efficient unboxing
2. Your Packaging Materials May Be Costing You More Than You Think
It’s not just about the box. As the saying goes, it’s what’s inside that counts. Too often, businesses assume that any protective packaging will do. But using the wrong materials can silently eat away at your margins.
Cheap fillers, weak cardboard, and nonrecyclable plastics might lower your up-front costs, but they can lead to:
- Higher damage rates
- Increased return volume
- Lower customer satisfaction
- More negative reviews
On the other end of the spectrum, excessively complex packaging products can slow down fulfillment, raise material costs, and contribute to unnecessary waste.
There’s a sweet spot between performance and price. The most efficient packaging materials are both durable and cost-effective. They’re strong enough to protect the product without adding unnecessary bulk.
3. Automation Isn’t Optional Anymore
If you’re still hand-taping boxes and applying labels one by one, you could be falling behind. This method can be slow, error-prone, and tough to scale, especially during peak seasons or other volume spikes.
Fortunately automation isn’t as complicated as it might seem. Simple tools such as box erectors, auto-tapers, and smart label printers are affordable and easy to integrate.
Automation helps provide:
- Faster fulfillment with fewer delays
- Consistent, professional packaging every time
- Lower labor costs and fewer packing mistakes
- The ability to scale smoothly during peak seasons
If you plan to grow, manual systems will have a hard time keeping up without increasing cost. Automation lets you stay efficient even when orders are flying in.
4. Your Entire Supply Chain Suffers from Poor Packaging
Inefficient packaging can have ripple effects across your entire supply chain.
As we mentioned above, oversize cartons waste pallet space and increase transportation costs. What’s more, poorly labeled boxes slow down pick-and-pack operations. Inadequate protection leads to more returns, and unpredictable packaging standards make inventory management a nightmare.
Wrong packaging just slows everything down.
Unfortunately, packaging inefficiencies are often invisible until something breaks, and by that time, the costs have already piled up. Better packaging leads to smoother logistics in the long run.
5. Branded Packaging Looks Great but Function Still Needs to Come First
Custom packaging has become a go-to move for eCommerce brands looking to impress buyers and build loyalty through unboxing experiences. Branded boxes, tissue paper, stickers—it all adds flair. But some of these design-heavy choices won’t deliver business value when they come at the expense of performance.
Carriers may happily sell you high-design, premium packaging products, but they won’t warn you when those materials:
- Increase your cost per shipment
- Offer minimal protection during transit
- Delay fulfillment due to complex assembly
What matters more than a great unboxing video is a package that arrives on time, in one piece, and with zero excess waste.
If your packaging isn’t functional and durable, it’s not serving your business, no matter how good it looks.
6. If You’re Not Tracking the Right Metrics, You’re Guessing
You probably know your shipping costs, but what about the stuff behind those numbers, like how much packaging waste you’re creating or how many returns are tied to damaged boxes?
Most carriers won’t bring this up, and that’s a problem. Because if you’re not measuring how well your packaging is actually working, you’re just guessing.
Here are some of the additional numbers business owners should be aware of:
- Box utilization — how much of each box is product vs. empty space
- Damage rate per shipment — how often things break in transit
- Cost per package — not just the postage but also materials and labor
- Throughput rate — how many packages your team can prep per hour
- Return rate due to packaging issues — a hidden cost that adds up fast
Once you start tracking these, it gets easier to spot the waste, fix the weak spots, and save money without cutting corners.
How ePost Helps You Optimize Your Packaging Process
Other carriers may focus on volume. At ePost, we focus on value and long-term viability. That means helping you optimize your packaging process not just for cost but for efficiency, scalability, and sustainability as well.
We work directly with clients to identify inefficiencies across their packaging operation, from material selection to workflow design. Whether you’re reworking your packaging line or expanding to meet demand, our team delivers packaging solutions that reduce waste, improve protection, and lower overall packaging costs.
But what truly sets us apart is our commitment to sustainable packaging. Sustainability is built into every recommendation we make.
We help brands:
- Shift to eco-friendly and recyclable packaging products that align with modern customer expectations
- Reduce their packaging footprint with smart design and right-sizing
- Implement sustainability initiatives that support both brand values and environmental goals
- Use near real-time data to monitor performance and make informed packaging decisions
We know that every packaging decision impacts your business. And by treating packaging as a system, we help you turn boxes into a strategic advantage.
If you’re launching sustainability initiatives, struggling to control packaging costs, or simply ready to improve the performance of your current packaging operation, ePost is here to help.
Quick Self-Audit: Is Your Packaging Actually Working for You?
Before you make another packaging decision, take a minute to audit your current setup. Ask yourself:
- Are we regularly getting hit with DIM weight fees because our packaging is too large for the product inside?
- Are our boxes and mailers right-sized, protective, and durable enough to prevent damage during shipping?
- Are we using eco-friendly, recyclable, or compostable materials, or just the cheapest options available?
- Could automation tools such as box erectors or labelers significantly improve our throughput and reduce labor costs?
- Are we tracking the right metrics—damage rates, material waste, box utilization—to drive better packaging decisions?
If you answered “no” or even “I’m not sure” to any of the above, it’s likely that your packaging is underperforming and costing you more than you think.
Let’s Optimize Your Packaging Together
Packaging shouldn’t be a source of hidden costs and missed opportunities. At ePost Global, we help you streamline, automate, and improve your packaging systems for better performance across the board. Let’s talk about how we can reduce packaging inefficiencies, support sustainability, and improve your customer experience—one box at a time.
