Good Boxes Aren't Enough on Their Own

You've bought a quality corrugated box — so your items are safe, right? Not necessarily. The box is only one part of the equation. Poor packing technique causes a surprising amount of damage in transit and storage, even when the box itself is perfectly sized and rated for the job.

Here are five of the most common packing mistakes and how to fix each one.

Mistake #1: Not Using Enough Void Fill

A box that's half-empty might seem fine until you realise the item is bouncing around inside during shipping. Even a small amount of movement causes wear, scratches, and breakage over time.

The fix: Fill all empty space with appropriate void fill — crumpled kraft paper, bubble wrap, foam inserts, or biodegradable packing peanuts. Shake the box gently; if you feel movement, add more fill. The item should feel firmly cushioned from all sides.

Mistake #2: Using Worn-Out or Second-Hand Boxes

Reusing boxes seems economical, but cardboard loses structural integrity with each use. A box that's been wet, compressed, or previously loaded loses a significant portion of its rated strength.

The fix: Inspect reused boxes carefully before use. Check corners, edges, and bottom seams. If there's any softness, creasing, or moisture damage, recycle the box and use a fresh one — especially for valuable or heavy items.

Mistake #3: Sealing the Box Incorrectly

A single strip of tape down the centre seam is one of the most common (and dangerous) shortcuts in packing. This method can pop open under even moderate stress.

The fix: Use the H-tape method — run tape along the centre seam and then along each side edge, forming an "H" shape. Use proper packing tape (not masking tape or duct tape, which don't adhere well to cardboard over time). For heavier boxes, tape the bottom in the same pattern.

Mistake #4: Overpacking the Box

Stuffing a box beyond its capacity bows the sides outward and weakens the bottom. An overpacked box is more likely to burst at the seams and is harder to seal properly.

The fix: If you're tempted to cram in more, use a larger box instead. Check the manufacturer's weight limit printed on the box bottom flap. Stay within it. Your back — and your items — will thank you.

Mistake #5: Poor Orientation of Items Inside the Box

Placing items in the wrong orientation — especially fragile ones — dramatically increases the risk of damage. Bottles placed on their sides can leak. Framed pictures laid flat in the wrong box can crack under stacking pressure.

The fix: Think about how your items will be oriented under pressure and during handling. Fragile items should be wrapped individually and placed in the centre of the box, away from walls. Heavy items go on the bottom. Mark the box clearly with "This Side Up" and "Fragile" if needed.

A Quick Reference: Packing Done Right

  • Choose the right size box — 5–7 cm clearance on all sides
  • Use fresh, undamaged boxes for valuable items
  • Fill all void space with cushioning material
  • Use the H-tape method on top and bottom seams
  • Never exceed the box's weight limit
  • Orient items correctly and label fragile boxes clearly

Getting these basics right makes a real difference in how well your items arrive — whether you're sending one parcel or packing an entire warehouse's worth of stock.