When you send products online, you can pick from many packaging types.
Corrugated boxes, like regular slotted containers, full overlap, auto-locking, and roll end styles, keep most items safe.
Paperboard and chipboard boxes are good for light products.
Rigid Boxes look fancy and are very strong.
Mailer boxes, folding cartons, padded and bubble mailers, and poly bags fit different sizes and shapes.
Dunnage, such as air pillows or paper, fills empty space and keeps things safe.
Picking the right ecommerce shipping boxes helps stop damage, saves money on shipping, and makes customers happy. Special packaging can help your brand and make opening the box fun.
Packaging Type | Market Share / Volume Share (2024) |
|---|---|
Corrugated Board Boxes | 51% global volume share |
Boxes and Cartons (format) | 62% of e-commerce packaging market |
Protective Packaging | 16.26% CAGR (growing segment) |
Flexible Mailers | Significant and growing segment |
Key Takeaways
Pick the best shipping box to keep products safe. This helps save money and makes customers pleased. Corrugated boxes are tough and good for the planet. They work well for many things, even breakable or heavy items. Use special boxes like auto-locking or roll end boxes. These make packing faster and unboxing more fun. Choose dunnage like air pillows or paper to fill empty spots. This keeps items safe while they ship. Use packaging that matches your product size and shipping way. This lowers costs and is better for the earth.
Types of Ecommerce Shipping Boxes
Corrugated Boxes
Corrugated boxes are the most used for shipping. They protect products well and cost less than other boxes. These boxes have wavy layers between flat sheets. The layers help absorb shocks and stop crushing. You can use corrugated boxes for handmade items, tech gear, subscription boxes, cosmetics, and lifestyle products. Many industries use these boxes, like electronics and food.
Tip: Corrugated boxes help you save money on shipping. They are light and easy to stack.
Key benefits of corrugated boxes:
Special coatings keep out moisture
You can add branding and inserts
Made from recycled materials, so they are eco-friendly
Easy to handle, store, and recycle
Common e-commerce products shipped in corrugated boxes:
Handmade crafts
Electronics
Cosmetics
Subscription kits
Regular Slotted Containers (RSC)
Regular Slotted Containers (RSC) are the basic shipping boxes for ecommerce. The flaps meet in the middle and you seal them with tape. RSC boxes use less material than other boxes, so you save money. You can fold them flat to store and keep your warehouse neat.
Structure and uses:
Made from recycled corrugated cardboard
Used for appliances, consumer goods, toys, and personal care items
Key benefits:
Good price for general use
Works for many sizes and weights
Simple to put together
Note: RSC boxes need more tape and padding for breakable items.
Full Overlap (FOL) Boxes
Full Overlap (FOL) boxes have flaps that cover the whole opening. This gives extra strength and protection. Use FOL boxes for heavy, fragile, or expensive items. The flaps add cushion and make the box stronger. This helps stop crushing and dents when shipping.
Structure and uses:
Flaps fully overlap for double layers on top and bottom
Best for electronics, industrial equipment, and long trips
Key benefits:
Strong and good for stacking
Better protection for rough handling
Great for products that need extra care
FOL boxes are good for shipping heavy or delicate products.
Auto-Locking Bottom Boxes
Auto-locking bottom boxes make packing fast and easy. The bottom locks by itself, so you do not need tape or glue. These boxes ship flat, so you save space and shipping costs. You can add your brand to auto-locking bottom boxes. They use less material and are recyclable, which helps the environment.
Structure and uses:
No need for glue or extra tape
Used for food, gifts, subscription boxes, toys, personal care, and clothes
Key benefits:
Fast to put together and pack
Saves money on labor and materials
Tamper-evident for security
Good for eco-friendly packaging
Auto-locking bottom boxes help ecommerce sellers pack faster and spend less.
Roll End Boxes (RELF, RETT)
Roll end boxes come in two styles: Roll End Front Tuck (REFT) and Roll End Tuck Top (RETT). These boxes have rounded flaps that tuck into the front or top. The lid stays locked in place. You use roll end boxes for subscription kits, master packing, and kitting. They close tightly and have double layers on the bottom and sides.
Feature/Aspect | Roll End Front Tuck (REFT) | Roll End Tuck Top (RETT) |
|---|---|---|
Structure | Rounded flaps on lid tuck into front, locking lid in place | Connected lid and front panel with locking flap between sides |
Lid Security | Locking flaps prevent lid from opening unexpectedly | No locking flap; requires tape or label to seal |
Material Usage | More material due to extra flaps | Uses minimal material, cost-saving |
Assembly Effort | Slightly more time to fold flaps | Quick loading, no extra flaps to fold |
Typical Applications | Subscription box packaging needing product protection | Industrial uses like master packing, kitting; efficient loading |
Consumer Experience | Secure but requires more effort to open | Easy to open without tools |
Protection Level | Enhanced protection through locking flaps | Double layer protection on bottom and sides |
Key benefits:
Lid stays closed for valuable products
Double layers protect fragile items
Simple to open and put together
Roll end boxes help make opening the box fun for your customers.
Other Types of E-commerce Packaging
Paperboard and Chipboard Boxes
Paperboard and chipboard boxes are common in stores and online. They work best for small and light things like makeup, phone chargers, or gifts. Chipboard is made from pressed recycled paper. It feels smooth and is easy to print on. Paperboard is almost the same but can be a bit thicker. Both types save money and space. But they do not protect heavy or breakable things as well as corrugated cardboard.
Feature | Chipboard (Paperboard) | Corrugated Cardboard |
|---|---|---|
Material Structure | Dense, smooth, compressed recycled paper pulp | Fluted inner layer between linerboards |
Strength & Durability | Lighter, less shock absorption, suitable for lightweight or premium retail packaging | Superior strength, shock absorption, ideal for heavier, fragile, or bulky items |
Suitability for Ecommerce | Best for small, lightweight products or premium retail display | Best for shipping heavier or fragile items, especially over long distances |
Cost | More cost-effective, space-efficient | Higher upfront cost but better protection |
Recycling & Eco-friendliness | Recyclable and eco-friendly | More widely recycled and better for rigorous shipping |
Tip: Use chipboard for nice-looking boxes in stores. Pick corrugated cardboard if you need more protection when shipping.
Rigid Boxes
Rigid boxes make products look fancy and special. You see them with expensive things like watches, perfume, and electronics. Rigid boxes keep their shape and stop damage. They are good for printing, embossing, or shiny foil designs. This helps your brand stand out. Many rigid boxes use materials that can be recycled. This is good for brands that care about the planet.
Rigid boxes look nice and protect expensive items.
They are easy to open and can be used again.
Using rigid boxes helps your business be more eco-friendly.
Folding Cartons
Folding cartons are light and simple to put together. They are great for food, makeup, and small gadgets. Folding cartons fold flat, so they save space and lower shipping costs. You can print your logo and colors on them. Folding cartons can be recycled and help the environment.
They cost less than rigid boxes and are easy to keep.
Custom designs make your brand easy to spot.
Custom Mailer Boxes
Custom mailer boxes protect products and show off your brand. You can print your logo or art right on the box. Choose green materials like recycled cardboard or fibers that break down. Custom boxes make opening the package fun and special. This makes people want to share their experience online.
Custom mailer boxes use less material and weigh less.
Simple and old-fashioned looks are popular now.
About 40% of shoppers post cool unboxing videos or photos, which helps your brand.
Note: Picking the right packaging can save money and help the earth. Lighter boxes use less fuel and make less pollution. This helps your online store be more green.
Mailers and Bags for Ecommerce
Padded and Bubble Mailers
Padded and bubble mailers are good for shipping small things. You can use them for jewelry, USB drives, makeup, and small electronics. The bubble layer inside gives soft padding. In tests, bubble mailers stayed strong and kept items safe from bumps. The outside is waterproof, so rain and water cannot get in. You do not need to worry about rips or holes when mailing.
Padded mailers feel nice and protect breakable things. They soak up shocks and stop damage to glass or delicate electronics. Many online sellers pick padded mailers because they keep products safe and help the planet. New kinds of padding, like plant-based ones, make these mailers even better for nature.
Tip: Pick padded mailers for breakable or expensive things. Bubble mailers are best for less breakable stuff like books or clothes.
Poly Bags and Paper Bags
Poly bags and paper bags are used a lot for soft or tough items. Poly bags keep clothes, accessories, and fabrics safe from water and dust. They are light, so you pay less to ship them. Poly bags do not tear easily and keep out water, so your things stay safe. You can recycle poly bags, which is good for the earth.
Paper bags are good for things that do not need much water protection. They work for dry foods, gifts, or things with strong boxes inside. Paper bags cost more than poly bags but can be composted or recycled. Both types let you print your logo or brand on them.
Aspect | Poly Bags | Paper Bags |
|---|---|---|
Cost | Cheaper to use | Costs more |
Sustainability | Can be recycled, good for the earth | Compostable, made from recycled paper |
Protection | Keeps out water and does not tear easily | Not as good at keeping out water |
Customization | Easy to print designs | Easy to print designs |
Foil-Sealed and Bottle Packaging
Foil-sealed bags help you send food and sensitive things. These bags keep out air and water, so food stays fresh. Foil-sealed bags are light, strong, and can be recycled. You can use them for snacks, coffee, or vitamins.
Bottle packaging is best for liquids, creams, and powders. Caps keep bottles closed and stop leaks. They also keep out dirt and stop people from opening them. Plastic caps are easy to open, and metal caps are stronger. Both types help your products last longer and make customers trust you.
Note: Foil-sealed and bottle packaging keep things safe from germs. They also help make online shopping better for the planet.
Dunnage and Internal Protection
Paper, Air Pillows, and Foam
When you pack products, you need dunnage. Dunnage keeps things safe inside the box. It fills empty spaces and stops items from moving. You can use paper, air pillows, or foam for protection.
Paper dunnage works well for fragile items. It absorbs shocks and stops scratches. Most paper dunnage can be recycled or composted. This makes it good for the environment. But paper takes up more space and costs more.
Air pillows are light and filled with air. They fit around products and add almost no weight. This helps lower shipping costs. Air pillows work best for light items and fill gaps. Some air pillows use compostable materials. This helps the planet. But air pillows can pop if you ship heavy or sharp things.
Foam dunnage gives strong protection for electronics. Foam absorbs impacts and keeps products still. Foam is heavier and not as eco-friendly as paper or air pillows.
Aspect | Paper Cushioning | Air Pillows | Foam |
|---|---|---|---|
Cost | Higher | Lower | Higher |
Environmental Impact | Biodegradable, recyclable | Recyclable, some compostable | Less eco-friendly |
Effectiveness | Great shock absorption | Good for light items | Best for heavy/fragile |
Storage Space | Bulky | Space-saving | Bulky |
Tip: Pick dunnage that matches your product’s weight and how breakable it is. This gives the best protection.
Choosing Dunnage for Shipping Boxes
You need to pick the right dunnage for each product. First, look at how breakable, heavy, or oddly shaped your item is. Fragile things like glass or electronics need bubble wrap or foam. Heavy tools need strong dunnage, like double-walled inserts or edge protectors.
For food, use insulated containers or moisture barrier bags. This keeps items fresh. Clothes need light dunnage, like tissue paper or poly mailers. This stops wrinkles and keeps them clean. Custom dunnage works best for large or odd-shaped products.
Here are some key things to think about:
Check if your product is breakable, heavy, or needs to stay dry.
Pick dunnage that absorbs shocks and keeps out moisture.
Use custom dunnage for special shapes or expensive items.
Make sure your dunnage follows safety and shipping rules.
Choose reusable or recyclable dunnage to help the environment.
Good dunnage keeps products safe and lowers returns. It also makes customers happy. When you use the right dunnage, you protect your brand and save money.
Choosing Ecommerce Shipping Boxes
Product Size and Fragility
First, measure your product’s length, width, and height. This helps you pick the right box. Leave extra space for padding if your item breaks easily. A box that is too small can crush your product. A box that is too big wastes money and materials. Fragile items need more padding to stay safe. Pick a box that fits both your product and the padding. Odd-shaped products may need custom boxes to stop them from moving. Heavy items need strong boxes to hold their weight.
Box Size | Typical Dimensions (inches) | Ideal Product Types |
|---|---|---|
Small | 5x5x5 | Jewelry, cosmetics, small breakables |
Medium | 14x10x6 | Clothing, shoes, electronics |
Large | 18x12x8 | Home goods, textiles |
Custom | Varies | Unique or oversized products |
Tip: Using the right box size helps stop damage. It saves money on shipping and makes customers happy.
Shipping Method and Customer Experience
How you ship things changes what packaging you need. Flat-rate shipping works best with boxes that fit standard sizes. Freight shipping is better for big or heavy items. If you offer different shipping choices, you help more customers. Many people want fast or flexible delivery. The right packaging helps you ship faster and spend less. Some businesses use software to match products with the best box. This lowers the number of boxes and shipping costs. It also makes customers happier.
Note: Giving choices like express or regular shipping can help you sell more and keep customers coming back.
Cost and Sustainability
Picking cheap and earth-friendly packaging helps your business grow. Use boxes made from recycled or biodegradable stuff like kraft paper. Using the right size box lowers shipping fees and waste. Lighter boxes cost less to ship. You can use green fillers like biodegradable peanuts or compostable tape. Some companies use tools to track shipping costs and pollution. This helps you save money and protect the planet. Using the right box also lowers returns and pollution.
Choose boxes you can recycle or compost.
Don’t use too much packing to save money and cut waste.
Use machines to pick the best box size for each order.
Offer carbon-neutral shipping for customers who care about the earth.
Using earth-friendly packaging helps customers trust your business and want to buy again.
Picking the right ecommerce shipping boxes keeps your products safe. It helps you save money and makes customers happy. If you use the right box for each item, you stop damage and returns. Easy returns help customers trust your business. Many people want packaging that is good for the earth and shows your brand. Using green materials and special designs makes your brand easy to spot and helps the planet. 📦🌱
FAQ
What is the best box for fragile items?
Use a corrugated box with lots of padding. Foam or air pillows help keep things safe. Double-walled boxes give even more protection. Always choose a box that fits your product well. Leave some space for dunnage to stop movement.
Can I recycle ecommerce shipping boxes?
Most corrugated, paperboard, and chipboard boxes can be recycled. Take off tape and labels before you recycle them. Many cities let you put these boxes in curbside recycling bins.
How do I choose the right box size?
First, measure your product’s length, width, and height. Add a little extra space for padding. Pick a box that fits your item closely. Big boxes waste money and packing. Small boxes might crush your product.
Are poly bags safe for shipping clothing?
Poly bags are good for shipping clothes. They keep out water and dust. Many poly bags can be recycled too. For more safety, use a padded mailer or add tissue paper.
What packaging helps my brand stand out?
Custom mailer boxes with your logo and colors make your brand easy to see. Using eco-friendly materials and fun designs also impresses customers. This makes people want to share their unboxing online.
