How to Get Your Cardboard Packaging Right the First Time

Start with what you are packing 

Before choosing a box size, it is worth thinking about what the packaging needs to do. 

• Is the product heavy or fragile? 

• Will it be stacked in storage? 

• Is it being sent by courier, packed onto pallets or moved between warehouses? 

• Does it need extra void fill or protective packaging inside? 

These details all make a difference. A box that works well for one product may not be the right fit for another, even if the dimensions look closely. 

Common cardboard packaging mistakes 

One of the most common issues is choosing a box that is too large. This can mean more void fill, more movement in transit and higher freight costs.

A box that is too small can be just as frustrating. It may be difficult to pack, place pressure on the product, or leave no room for extra protection.

Strength is another important factor. Not all cardboard packaging is made for the same job. A lightweight carton may be fine for general storage, while heavier or bulkier goods may need a stronger cardboard box, pallet box or tray.

It is also easy to underestimate how much packaging you will need. Running out of boxes during a busy period can slow down dispatch, while over-ordering can take up valuable warehouse space. 

Do not forget about void fill 

Choosing the right box is only part of the process. What goes inside the box matters just as much.

Void fill is used to fill the empty space around a product once it has been packed. Without it, products can shift, knock against each other or hit the sides of the carton during transport. This is where damage often happens, even when the outside of the box looks fine.

The amount of void fill paper packaging you need depends on the product, the carton size and how the order is being shipped. A small amount of movement inside the box can become a bigger issue once the carton is stacked, loaded, handled by couriers or moved through a warehouse.

This is why box sizing, and void fill should be considered together. If the carton is too large, you may need more void fill than necessary, which adds cost, packing time and waste. If the carton is too tight, there may not be enough room to properly cushion or protect the product. 

For lighter items, simple paper void fill packaging may be enough to stop movement and improve presentation. For fragile, sharp-edged or higher-value goods, a stronger protective option may be needed, such as corrugated cardboard wrap, protective sheets, foam or other cushioning materials.

Corrugated cardboard rolls are a practical option for wrapping awkward-shaped products, separating items inside a carton, or adding an extra protective layer before the product is boxed. They can also help protect surfaces from scratches and scuffs during storage or transport.

The goal is not to overpack. It is to use the right amount of packaging in the right places. Good void fill should hold the product securely, protect it from impact and make the packing process easy for the team.

When the box and void fill work together, you can reduce product movement, improve the customer experience and lower the risk of returns or damaged stock. 

The hidden cost of using the wrong void fill 

Poor void fill can cost more than the packaging itself.

If products arrive damaged, the cost is not just the replacement item. It can also mean extra freight, customer complaints, credits, returns and time spent fixing the issue. For busy warehouses, even small packaging problems can slow down dispatch when staff need to make boxes work with the wrong materials.

Using the right void fill helps keep packing consistent. It gives the team a clear process to follow and helps products leave the warehouse in the same condition every time.