You picked the product, boxed the order and sent it off. Then it turns up dented, crushed, or the customer opens it to find the item rattling around loose inside. It’s a frustrating way to lose a sale you already made.
You’re not alone in this. A recent Compare the Market survey found 48.26% of Australians who bought something online in the past 12 months ran into a delivery problem, up from 42.84% the year before. A good share of that comes down to how the item was packed, not how it was carried.
This guide walks through exactly how to pack your product so it survives the trip, from choosing the right box and cushioning to how to fold a packing box shut so it doesn’t pop open in transit. It also covers fragile items, common mistakes, and how to size a box correctly the first time.
Follow it and packing stops being a guessing game.
Here’s Everything You Need to Know in Under a Minute
- Match the box or mailer to the product; too much empty space is the most common cause of damage
- Cushion the item on every side, then fill any remaining gaps so nothing can shift
- Fold the smaller flaps in first, then the larger ones over the top, before sealing
- Seal every seam with the H-taping method rather than a single strip down the middle
- Label fragile or awkward items clearly before the box leaves your hands
Table of Contents
- What You Need Before You Start Packing
- How to Pack Your Product Step by Step
- How to Fold a Packing Box Correctly
- How to Pack Fragile or Awkward-Shaped Products
- How to Pack Multiple Items in One Box
- Choosing the Right Box Size for Your Product
- Common Packing Mistakes to Avoid
- How to Pack Sustainably Without Losing Protection
- Why Aussie Businesses Trust The Boxman
- Frequently Asked Questions
- Pack It Once, Pack It Right
What You Need Before You Start Packing
Packing a product properly starts before the item ever touches a box. Get the materials right first and the rest of the process is quick and repeatable.
Boxes and Mailers
Use sturdy packing boxes for general retail products, and heavier-duty shipping boxes for bulkier or heavier items. For flat, lightweight goods like documents or small gifts, a padded mailing box is quicker to assemble and just as secure.
Protective Fill
Prevent the product from shifting or absorbing shock with bubble wrap, packing peanuts, air pillows or crumpled paper. Whatever you use, it needs to reach every side of the item, not just sit on top.
Sealing Supplies
Secure every seam and edge with heavy-duty packing tape and labels. A single strip down the centre isn’t enough once the box has any real weight in it.
How to Pack Your Product Step by Step
Once you’ve got the right materials, packing a product safely comes down to five steps in order.
- Fit the item. Choose a box or mailer that fits your product snugly, without forcing it in or leaving excessive empty room around it.
- Wrap and cushion. Wrap fragile items individually in bubble wrap or foam so they can’t knock against each other or the sides of the box.
- Fill the voids. Pack any empty space tightly with filler material so the product can’t rattle or slide during transit. According to Packhelp’s shipping guide, around two to three centimetres of cushioning on every side is a safe general rule.
- Add a personal touch (optional). A branded insert, tissue paper or a short thank-you note costs little and improves the unboxing experience.
- Seal and label. Close the outer carton with strong tape and apply a clear, correct shipping label to the largest flat surface.
How to Fold a Packing Box Correctly
A box that’s packed well but folded badly can still fail. Getting the flaps and tape right is what actually keeps the box shut for the whole trip.
Folding the Flaps in the Right Order
Fold the two smaller side flaps in first, then bring the two larger flaps down over the top of them. Press along the centre seam to flatten the join before you tape it, so the lid sits flush rather than peaked.
Seal It With the H-Taping Method
Run one strip of tape along the centre seam, then two shorter strips across each end where the flaps meet the sides. Laid out, it forms an H shape, and it’s the standard most couriers rely on because it reinforces the weakest points on the box rather than just the middle.
This method is confirmed as best practice by Packola’s box-folding guide, which recommends reinforcing both the top and bottom seams the same way. Do the bottom of the box first, before you add the product, then repeat on the top once it’s packed.
An Alternative for Light, Non-Fragile Items
If you don’t have tape on hand, you can fold all four flaps over each other in a clockwise direction and tuck the last corner under the first. It holds well enough for short trips with light contents, but it isn’t secure enough for anything with real weight or fragility. When in doubt, tape it.
How to Pack Fragile or Awkward-Shaped Products
Standard boxes work for most orders, but some products need purpose-built packaging rather than extra bubble wrap in a generic carton.
- Screens and flat electronics fit best in dedicated TV boxes, which hold the item rigid instead of relying on padding to stop it flexing.
- Framed pictures, mirrors and artwork should go in purpose-built art boxes rather than a standard carton with corner protectors.
- Glass, crockery and other breakables need individual wrapping in multiple layers, with each piece separated so nothing touches another hard surface.
- Odd shapes that don’t sit flush in a standard box are exactly where a custom size earns its cost, since there’s no gap for the item to shift into.
Label anything fragile clearly on at least two sides of the box, and add directional arrows if the contents need to stay upright.
How to Pack Multiple Items in One Box
Combined orders are where most damage happens, because heavier items shift and crush lighter ones underneath during transit.
- Put the heaviest item on the bottom and build lighter items up from there
- Wrap each item on its own, even if they’re going in the same box together
- Add a layer of filler between items, not just around the outside of the whole group
- Keep sharp or hard-edged products away from anything that can be scratched or dented
If the combined order is heavy or oddly balanced, size up to the next box rather than forcing everything into a tight fit. A box that’s slightly too big and well padded beats one that’s stuffed to the seams.
Choosing the Right Box Size for Your Product
Measure the product’s length, width and height, then add roughly 2 to 5 centimetres on each dimension for cushioning. A box that’s too big wastes space and money; one that’s too small leaves no room to protect the item at all.
| What You’re Packing | Best Fit |
|---|---|
| General retail products | Standard packing box |
| Documents, small gifts, light goods | Self-locking mailing box |
| TVs and flat screens | Dedicated TV box |
| Framed art or mirrors | Dedicated art box |
| Unusual shapes or sizes | Made-to-measure custom box |
Box size also affects what you pay to send it. Most couriers charge on cubic weight once a box is oversized, so an unnecessarily large box can cost more than the postage alone. Our shipping cost guide breaks down where those charges come from.
If you regularly ship the same product, our shipping box size guide covers standard Australian dimensions in more detail. For products that never quite fit a standard size, it’s worth reading how to build your own cardboard box to the exact dimensions you need.
Common Packing Mistakes to Avoid
Most damaged orders trace back to one of a handful of avoidable mistakes.
- Leaving too much empty space, so the product has room to shift and hit the sides on every bump in transit
- Reusing an old box with weakened seams or splits, which can give way under the weight of a new item
- Taping only the centre seam instead of using the full H method, leaving the weakest points unsupported
- Wrapping several fragile items together instead of individually, so they knock against each other inside the box
- Guessing the box size instead of measuring the product first, which usually means too much or too little room
How to Pack Sustainably Without Losing Protection
Protecting the product and packing responsibly aren’t opposites. A few small changes cut waste without adding any risk of damage.
- Reuse boxes that are still structurally sound, once old labels and tape are removed
- Choose paper-based filler over loose plastic void-fill where the product allows it
- Right-size the box in the first place, since a smaller box needs less filler overall
- Keep cardboard offcuts on hand to use as padding for the next order
Why Aussie Businesses Trust The Boxman
When it comes to packaging, one size does not fit all. The Boxman specialises in custom cardboard boxes made to measure for your specific product, alongside a wide range of off-the-shelf boxes and packing materials for everyday orders.
We’re a Western Australian-owned business, manufacturing primarily Australian stock locally in the Perth metro area, and we offer fast delivery or in-store pick up whichever suits your workflow better.
We’re also committed to packaging made from renewable and recycled materials, so protecting your product doesn’t have to come at the environment’s expense. If you’re weighing up boxes versus mailers for your specific product range, our ecommerce packaging guide breaks down the options in more detail.
Frequently Asked Questions
How Do You Pack Your Own Products?
Choose a box or mailer that fits the item with a small allowance for padding, cushion it on every side, then fill any remaining gaps so nothing can move. Fold and seal the box using the H-taping method, then label it clearly with the delivery address and any handling notes before it leaves your hands.
What Are the 5 Requirements of Packaging?
Good packaging needs to contain the product, protect it from damage, apportion it into a sensible unit for handling, unitise multiple items for easier transport, and stay convenient enough for the customer to open and dispose of. Miss any one of these and the packaging isn’t doing its job, no matter how tidy the box looks.
What Is Self-Packaging?
Self-packaging is when a business or individual packs their own orders in-house, buying boxes and packing supplies rather than outsourcing to a fulfilment centre. It works well for smaller order volumes, as long as you follow a consistent process so quality doesn’t slip as orders grow.
What Are the 7 Types of Packaging?
The main categories are primary packaging that touches the product directly, secondary packaging like the retail box or mailer, and tertiary packaging used for bulk transport such as pallets, alongside flexible, rigid, semi-rigid and protective packaging grouped by material and structure. Most small businesses only deal with primary and secondary packaging day to day.
How Can I Design My Own Packaging?
Start with the exact size and shape of your product, then choose a box style that fits it with minimal wasted space. From there, work out branding, closures and any protective inserts, and look at made-to-measure custom boxes for products a standard box doesn’t suit.
