Why is packaging bigger than it needs to be?

Frustrated by tiny products in huge boxes? This waste increases costs and harms our planet. Let's find out why this happens and how we can fix it together.

Packaging is often oversized for a few key reasons. Companies use standard box sizes to cut costs¹. They also need extra room for protective materials like bubble wrap². Sometimes, a larger box is used for marketing³, making the product look more substantial on the shelf.

It feels strange, right? A big box can make a product seem more valuable, but it can also feel deceptive. The truth is, the size of a package isn't just a random choice; it's a careful decision with big consequences. This brings us to a more fundamental question about the boxes we use every day.

Why is the size of the carton important?

Think box size is a minor detail? Wrong sizes lead to damaged goods and high shipping costs. Let's see why getting the carton size right is so important.

Carton size is crucial for product safety, cost, and brand perception. The right size prevents items from shifting and breaking during transit. It also keeps shipping costs down and gives customers a professional, thoughtful unboxing experience⁴, which builds trust in your brand.

Over my 16 years in this industry, I have seen clients save thousands of dollars just by auditing their box sizes⁵. The impact of size is huge and touches several parts of a business. A box that is too big costs more in three ways: the material for the box itself, the void fill needed to stop the product from moving⁶, and the shipping fees. Carriers often charge based on dimensional weight⁷, not just actual weight. This means a large, light box can cost more to ship than a small, heavy one. A correctly sized box is a win for your budget, your product's safety, and your customer's perception of your brand. It shows you are thoughtful and efficient.

Why is it important to use the right box size for packing?

Ever just grabbed the nearest box? This common shortcut can lead to broken products and costly returns. Let's explore why using the right size is a non-negotiable step.

Using the right box size is critical to prevent damage. A perfect fit stops the product from moving, which is the main cause of breakage. It makes your protective fillers work better, saves you money on returns, and keeps your customers happy with their purchase.

I remember a client who sold delicate ceramic mugs. Their breakage rate was very high, and they were losing money and customers. When my team looked at their process, we found their packing box was about two inches too wide on every side. They filled the space with packing peanuts, but the mugs still had room to shift and crack during shipping. We designed a simple custom-fit box⁸ for them. This one change dropped their damage claims by over 90% almost overnight. This proves that using the right size is about creating a complete 'shipping system⁹'. The box and the cushioning must work together. A snug fit immobilizes the item¹⁰, which is the most important factor in preventing damage. It also creates a much better unboxing moment for the customer; it feels professional and intentional, not messy and careless.

Why is packaging so important in business?

Is packaging just a box? Many businesses think so, missing a powerful marketing tool. Your package is often the first physical contact a customer has with your brand.

Packaging is a business essential. It protects the product, but it also tells your brand's story. Great packaging grabs attention on the shelf¹¹, communicates value, and creates a memorable unboxing experience¹². It is a powerful tool for marketing, sales, and building customer loyalty.

Packaging does so much more than just hold a product. It is your silent salesperson. I worked with a startup that sold amazing organic snacks, but their packaging was plain and looked like every other snack on the shelf. We helped them redesign their boxes with bold, natural colors and a unique texture that felt good to hold. We also added a small window so people could see the quality of the product inside. Sales jumped 40% in three months. The product didn't change, but its ability to communicate on the shelf did. Your package is a critical touchpoint¹³. It needs to grab attention, tell your brand's story, make an emotional connection, and provide essential information, like ingredients or instructions. It’s not just a business cost; it's a powerful investment in your brand’s growth.

Why is cardboard packaging better?

With so many materials available, choosing one is tough. A wrong choice can hurt your budget and brand. Let's explore why cardboard is often the smartest, most versatile option.

Cardboard often wins because it's a great all-rounder. It's affordable, lightweight, and easy to print on for amazing branding. Plus, it's recyclable and biodegradable, which is a huge plus for environmentally conscious customers. This combination makes it a smart and responsible choice for many products.

When I started Giftspack, I was amazed by how versatile cardboard could be. It's not just one material. There are many different types, from thin paperboard for cosmetic boxes to strong, double-wall corrugated board for shipping heavy electronics. The key is understanding the material's properties and matching them to the product's needs. For a product designer like Peter, knowing the difference between flute sizes or board strengths is essential. This expertise turns a simple "cardboard box" into a precisely engineered protective solution. Its biggest advantage is the balance it offers¹⁴. It gives you strength, great branding opportunities, and sustainability at a reasonable cost. While it has weaknesses, like not being waterproof, its overall benefits make it the top choice for a huge range of products.

Conclusion

Choosing the right package size isn't just about saving space. It's about protecting your product, building your brand, and making a smart, sustainable choice for your business.