How to Pack a Box So It Survives Shipping

Most shipping damage isn't the carrier's fault — it's a packing problem. Parcels get dropped, stacked, and vibrated for hours. The good news: a few minutes of correct packing prevents the vast majority of damage claims and refunds.

Start with the right box

Damage prevention begins before you pack. Use a box sized close to the product (with room for cushioning) and a board grade that matches the weight. Reusing a soft, previously-shipped box is a false economy — its strength is already spent.

Cushion on every side

The golden rule: your product should never touch the box wall and should not move when you shake the sealed parcel. Wrap the item, then fill the gaps so nothing shifts.

• Void fill (paper, air pillows, biodegradable packing peanuts) keeps the product centered.
• Bubble or foam protects surfaces and corners.
• Double-boxing (a padded inner box inside a larger one) is worth it for fragile or high-value goods.

Seal it properly

Use the H-taping method: tape the center seam and both edge seams on the top and bottom of the box. This stops the flaps from popping open under pressure. Use proper packing tape — not office or masking tape — and run two strips over each seam for heavier parcels.

Protect the label and edges

Place the shipping label on the largest flat face, away from seams, and make sure it won't be covered by tape glare or crushed at a corner. Reinforce edges on heavier boxes, since corners take the most abuse in transit.

Test before you scale

Before shipping a new product at volume, pack one and shake it, drop it from waist height, and check for movement or damage. If the product shifts or the box flexes, add cushioning or step up the board grade. A five-minute drop test is cheaper than a wave of "arrived broken" emails.

Stock up on protective packaging

Get sturdy shipping boxes and the void fill, tape and mailers to go with them — everything you need to pack parcels that survive the journey and protect your reviews.