- \n
- Match box strength and cushioning to your product\u2019s weight, fragility and journey.<\/li>\n
- Compare extra packaging costs with the damage and replacement costs you could avoid.<\/li>\n
- Use branded tissue, stickers and tape to add personality to your protective packaging.<\/li>\n
- Choose materials your customers can dispose of easily, with clear instructions for each layer.<\/li>\n<\/ul>\n <\/div>\n <\/div>\n <\/div>\n<\/section>\n\n\n\n
<\/p>\n\n\n\n
\n \n\n\n\n Give every order a better send-off. <\/div>\n\n\n Explore VistaPrint custom shipping supplies to find packaging that works for your products and your brand. <\/div>\n <\/div>\n\n\n \n\n Design yours today<\/a>\n <\/div>\n <\/div>\n <\/div>\n<\/section>\n\n\n<\/p>\n\n\n\n
Why packaging protection matters: Transit risks and damage costs<\/h2>\n\n\n\n
Packaging protection helps products withstand impact, pressure, movement and moisture on their way to your customers. Your protective packaging solutions need to address the risks your product actually faces, so adding more paper won\u2019t necessarily solve a weak box or an unsupported handle. One drop can crack a jar, while the weight of stacked parcels can crush a box. Repeated vibration can also rub surfaces together or let an item work its way through loose filling. <\/p>\n\n\n\n
\n \n\n\n Tip <\/div>\n\nTo understand how different packaging layers work and support one another, read our guide to the types of packaging<\/a>.<\/p>\n <\/div>\n <\/div>\n <\/div>\n<\/section>\n\n\n\n
<\/p>\n\n\n
\n![\"Cardboard](\"https:\/\/res.cloudinary.com\/vistaprint\/images\/w_1024,h_1024,c_fill,g_auto\/f_auto,q_auto\/v1793025084\/ideas-and-advice-prod\/blogadmin\/Cardboard-box-packaging\/Cardboard-box-packaging.png?_i=AA\")
<\/figure>\n<\/div>\n\n\n<\/p>\n\n\n\n
Damage costs go beyond replacing stock. Depending on how you resolve the problem, you might also pay for replacement delivery, return postage, extra packaging and customer support time. There\u2019s a possible longer-term cost, too, if a disappointed customer decides not to order again.<\/p>\n\n\n\n
To compare options, use this calculation:<\/p>\n\n\n\n
Packaging ROI (%) = [(estimate of damage costs avoided \u2212 extra packaging costs) \u00f7 extra packaging costs] \u00d7 100<\/strong><\/p>\n\n\n\n
For example, if you ship 1,000 orders monthly and spend $2 on protective materials per order, a 5% increase adds $0.10 per order, or $100 monthly. If testing shows that the change reduces damaged orders from 20 to 10, and each incident costs $40 to resolve, you avoid $400 in costs. After the extra packaging spend, that\u2019s $300 saved and a 300% return on the additional investment.<\/p>\n\n\n\n
This is just an illustration, not a promised result. Spending 3\u20135% more only pays off if it fixes a real problem, so track your damage rates before and after making the changes. <\/p>\n\n\n
\n![\"A](\"https:\/\/res.cloudinary.com\/vistaprint\/images\/w_1024,h_557,c_scale\/f_auto,q_auto\/v1793025112\/ideas-and-advice-prod\/blogadmin\/A-black-cardboard-box-with-an-illustration\/A-black-cardboard-box-with-an-illustration.png?_i=AA\")
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Choose the right outer containers: Mailer vs. shipping vs. product boxes<\/h2>\n\n\n\n
An outer container, or tertiary packaging, provides the structure that holds your product and its protective materials together during delivery.<\/p>\n\n\n\n
Product boxes work well for retail presentation.<\/strong> Folding custom product boxes<\/a> are a form of primary packaging and can give you space for branding and product information. However, they generally need a shipping container around them for parcel delivery. A carton that looks great on a shelf hasn\u2019t necessarily been designed to survive sorting equipment or pressure from other parcels.<\/p>\n\n\n\n
Corrugated mailer boxes suit many smaller online orders.<\/strong> Their folding construction and opening lid work well for subscription kits, clothing and gifts. VistaPrint\u2019s custom mailer boxes<\/a> bring branding inside and out, while the corrugated board provides structure. Choose a size that leaves room for the cushioning your product needs, then follow the closure instructions before shipping.<\/p>\n\n\n\n
Shipping boxes suit larger orders and products that need more packing space.<\/strong> Traditional shipping boxes<\/a> have flaps that you seal with packing tape. They\u2019re useful for multi-item orders, bulky products and an inner retail box surrounded by cushioning, but the name alone doesn\u2019t mean a box is heavy-duty. Check its construction and recommended load.<\/p>\n\n\n\n
Choose between these types of protective packaging by considering your parcels\u2019 packed weight, fragility and handling conditions. A short journey can still involve drops, while warehouse storage or multiple transfers may need stronger board. If you use pallet shipments, you should pay attention to their stacking patterns and load restraint.<\/p>\n\n\n\n
\n \n\n\n Tip <\/div>\n\nA corrugated mailer may let you skip an extra outer box for a subscription or gift order, if the packed design offers enough protection. Test it before removing a layer. You can compare custom packaging solutions<\/a> with your product measurements, including the space needed for void fill shipping materials.<\/p>\n <\/div>\n <\/div>\n <\/div>\n<\/section>\n\n\n\n
<\/p>\n\n\n\n
Understanding board and stock options: How material and construction affect strength<\/h2>\n\n\n\n
Corrugated board combines flat paper liners with a wavy middle layer, called fluting, to create a lightweight structure that resists pressure.<\/p>\n\n\n
\n![\"A](\"https:\/\/res.cloudinary.com\/vistaprint\/images\/w_1024,h_768,c_scale\/f_auto,q_auto\/v1793025138\/ideas-and-advice-prod\/blogadmin\/A-stack-of-colorful-cardboard-boxes\/A-stack-of-colorful-cardboard-boxes.png?_i=AA\")
<\/figure>\n<\/div>\n\n\n<\/p>\n\n\n\n
Paper weight, board thickness and construction all influence the performance of your board. Heavier linerboard can add strength, but a thickness measurement alone won\u2019t tell you how well a finished box will protect your product. Folding carton stock is different again, since it doesn\u2019t have the fluted layer found in corrugated boxes.<\/p>\n\n\n\n
These are the main features to compare:<\/p>\n\n\n\n
- \n
- E-flute:<\/strong> A thin flute profile that provides a relatively smooth printing surface and a compact box shape. VistaPrint uses E-flute for its custom mailer boxes.<\/li>\n\n\n\n
- B-flute and C-flute:<\/strong> Thicker profiles than E-flute, with different combinations of cushioning and crush resistance. The best choice depends on the full board specification.<\/li>\n\n\n\n
- Single-wall construction:<\/strong> One fluted layer between two liners, suitable for many everyday shipments when correctly specified.<\/li>\n\n\n\n
- Double-wall construction:<\/strong> Two fluted layers between three liners, often useful when heavier contents or stacking conditions require more strength.<\/li>\n<\/ul>\n\n\n\n
An Edge Crush Test, or ECT, measures how much force a sample of corrugated board withstands when compressed on its edge. It helps assess stacking performance, but it isn\u2019t a maximum product weight or a guarantee of the finished box\u2019s strength. Box size, construction, humidity and storage conditions also matter.<\/p>\n\n\n\n
Ask your supplier about suitable loads and protection against crushing, punctures and bursting, rather than choosing protective packaging materials by their appearance alone. Paper based protective packaging can do a lot of the work, but it still needs the right construction for the job. Try packaging samples<\/a> to check fit and assembly before committing to a larger order.<\/p>\n\n\n
\n![\"Someone](\"https:\/\/res.cloudinary.com\/vistaprint\/images\/w_1024,h_768,c_scale\/f_auto,q_auto\/v1793025176\/ideas-and-advice-prod\/blogadmin\/light-pink-branded-cardboard-boxes\/light-pink-branded-cardboard-boxes.png?_i=AA\")
<\/figure>\n<\/div>\n\n\n<\/p>\n\n\n\n
Matching product risk profiles to protective materials<\/h3>\n\n\n\n
The right protective materials keep an item in place, cushion impacts and protect the parts most likely to break or mark. Use this decision table as a starting point, then test the complete package with your actual product.<\/p>\n\n\n\n
- B-flute and C-flute:<\/strong> Thicker profiles than E-flute, with different combinations of cushioning and crush resistance. The best choice depends on the full board specification.<\/li>\n\n\n\n
- E-flute:<\/strong> A thin flute profile that provides a relatively smooth printing surface and a compact box shape. VistaPrint uses E-flute for its custom mailer boxes.<\/li>\n\n\n\n
![\"Someone](\"https:\/\/res.cloudinary.com\/vistaprint\/images\/w_768,h_768,c_fill,g_auto\/f_auto,q_auto\/v1793025195\/ideas-and-advice-prod\/blogadmin\/blue-branded-cardboard-box\/blue-branded-cardboard-box.png?_i=AA\")
<\/figure>\n<\/div>\n\n\n![\"Jewellery](\"https:\/\/res.cloudinary.com\/vistaprint\/images\/w_1024,h_1024,c_fill,g_auto\/f_auto,q_auto\/v1793025222\/ideas-and-advice-prod\/blogadmin\/Jewellery-packaged-in-a-cardboard-box-with-protective-filler\/Jewellery-packaged-in-a-cardboard-box-with-protective-filler.png?_i=AA\")
<\/figure>\n<\/div>\n\n\n![\"A](\"https:\/\/res.cloudinary.com\/vistaprint\/images\/w_1024,h_768,c_scale\/f_auto,q_auto\/v1793025250\/ideas-and-advice-prod\/blogadmin\/Red-branded-sticker-being-attached-to-a-white-cardboard-box\/Red-branded-sticker-being-attached-to-a-white-cardboard-box.png?_i=AA\")
<\/figure>\n<\/div>\n\n\n