Packaging goods for shipping: essential guide for businesses

Assessing your product

When deciding how to package your products, there are several important factors to consider. Think about the weight of your item, how fragile or valuable it is, and whether it requires special conditions such as temperature or humidity control. You should also check if there are specific packaging regulations—especially for categories like food or cosmetics.

It’s equally important to factor packaging costs into your product pricing, as this will impact your overall budget. Additionally, some everyday items, such as perfumes or electronics, may be classified as dangerous goods and require special packaging and handling. Taking all these elements into account will help ensure your products are shipped safely, compliantly, and cost-effectively.

Choosing appropriate packaging materials

There are two main types of packaging to consider: external and internal.

External packaging is typically the outer box used to ship your product. In most cases, this will be a sturdy corrugated cardboard box. It’s important to choose high-quality materials and avoid reusing old boxes, as they can lose strength and may not properly protect your goods during transit.

Internal packaging is used to protect the product inside the box by cushioning it and preventing movement. While materials like Styrofoam were once popular, they are now restricted in many countries due to environmental concerns. Today, businesses can choose from a variety of alternatives depending on their needs, whether for shock absorption, filling empty spaces, protecting fragile items, or separating multiple products within the same package.

Below is a simple overview of common packaging materials and their best uses.

Protecting your goods

Not all cardboard boxes are the same, and you need to choose the right type for your external packaging. For heavier or more fragile items, double or triple-wall boxes are more appropriate. There should be a manufacturer stamp which tells you more about the strength and durability of the box or, failing that, consult your box supplier.

For internal protection, biodegradable air peanuts are a greener alternative to styrofoam. Bubble wrap also does a good job of cushioning and protecting your product but, again, this is a traditional plastic-based packaging material and corrugated bubble wrap is a lot greener. Foam wrap, air pillows, crumpled paper, corrugated inserts and shredded cardboard are all other alternatives for protecting your goods – you just need to decide which is most suitable

Top tips for safe shipping:

• Wrap items individually – This helps protect each product from shocks, vibrations, and potential damage during transit.
• Use dividers – Ideal for shipping multiple items, dividers prevent products from colliding and breaking.
• Minimize movement inside the box – Secure items with proper cushioning to reduce the risk of damage.
• Position items in the center – Place products in the middle of the box and surround them with padding to keep them stable and well-protected.

Marketing and personalized packaging

While packaging’s primary purpose is to protect your product so it can be safely delivered to your Customer, it can also do so much more.

Packaging can be a powerful marketing tool, allowing communication with your Customer when they’re feeling most positive towards your brand – when their order arrives. At its most basic, you can use packaging to bolster your brand image using consistent colors, logos, messaging, typography and other brand elements. While your outer packaging may be a cardboard box, it needn’t just be plain brown! Consider using packing tape in your brand colors and custom-designed labels.

You can also synergize your packaging with your advertising. For example, if you’re running a social media campaign using a particular headline, why not look into adding it to your packaging? You can also cross-promote your social media campaign by adding a hashtag.

Other opportunities include: tying in your packaging with particular events – for example, Valentine’s Day or Christmas; including a personalized, handwritten thank-you card (perhaps with a personal discount code); and adding free samples of related products.

Creative packaging, personalization, free samples and discounts are all powerful ways of encouraging Customer loyalty and repeat purchases.

Packaging for quick and easy returns

Returns are an inevitable part of running an eCommerce business. While offering free returns can increase costs, many customers expect this option and may only buy from retailers who provide it. It’s important to evaluate what works best for your business and customer expectations.

That said, returns can also be an opportunity to strengthen customer loyalty. By making the process simple and hassle-free, you increase the chances that customers will shop with you again, even if their initial purchase didn’t meet their needs. Always include clear return instructions and a return label to streamline the process.

When it comes to packaging, choose solutions that are easy to open and reuse, such as boxes with perforations or resealable adhesive strips. A well-designed returns experience can turn a potential inconvenience into a positive interaction and help your business stand out from competitors.

Sustainable packaging

Sustainability has become a major priority for today’s consumers, and using eco-friendly packaging can significantly influence how your brand is perceived.

Sustainable packaging—also known as green or eco packaging—refers to solutions designed to minimize environmental impact. This can be achieved by reducing unnecessary packaging, using recyclable or biodegradable materials, and relying on more sustainable production processes.

So, what steps can you take? Start by minimizing waste and choosing packaging that fits your product properly. Oversized packaging not only increases costs but can also frustrate customers and harm your brand image. Right-sized, environmentally conscious packaging helps improve both efficiency and customer satisfaction.

As for packaging materials, new alternatives are being developed all the time. As mentioned above, biodegradable packaging peanuts can be used instead of styrofoam and corrugated cardboard bubble wrap instead of traditional plastic-based bubble wrap. Air pillows made from recycled or biodegradable materials are another alternative. Corn starch could be used instead of plastic. And if only plastic will do, there are now biodegradable and recycled plastics available. Organic ecological textiles are also becoming more popular, includingorganic cotton wool for cushioning, linen and poplin anti-scratch covers, and tape made from hemp.

And finally, try to source cardboard boxes and paper that have been recycled or certified to support sustainably managed forests.

For more details, read our article on green packaging.

Other considerations when shipping overseas

Of course, packaging is important. But, no matter how much thought you put into it, it could end up pointless if Customers are disappointed by a needless delay to their shipment or annoyed by surprise additional costs.

We can help you navigate international trade by enabling you to calculate your customs duty, tax and other fees, so you can pay them up front. Plus, you can get the correct HS (Harmonized System) codes and check your shipment’s compliance with any country’s import and export regulations.

You can do it all, using our free Global Trade Services toolkit.

Packaging Basics Checklist

• Assess your product

• Choose appropriate packaging materials

• Ensure your goods are protected

• Use your packaging as a marketing tool

• Make sure it’s returns-friendly

• Choose green packaging alternatives

• Navigate customs with our Global Trade Services toolkit

So, your packaging will ensure your shipment arrives at its destination in one piece, but what about on time? That’s where DHL has you covered. With a DHL Express Business Account, you’ll have access to a range of expedited shipping solutions to help you meet your customers’ expectations.