For many SMEs, shipping is the silent line item that keeps creeping up. Courier tariffs rise by a few per cent each year, but the more significant increases often stem from decisions made at the packing bench. As carriers now charge largely based on volumetric weight and regulators impose steeper penalties for incorrectly declared goods, even a “small” packaging error can wipe out the margin on an otherwise well-priced product.
These three common mistakes come up time and again. Each is easy to fix, yet together, they can add as much as 20–30% to your landed cost. Find out below the pitfalls and simple fixes you can implement this week.
1. Over-Boxing: Paying to Ship Air
The problem
When the outer carton is significantly larger than the item inside, carriers charge for the space you take up, not the weight you move. Up to 15% in added volumetric weight has been measured on otherwise light parcels, simply because the nearest available box was too big.
Cost impact
- Higher volumetric (DIM) weight charges at every stage of delivery
- Risk of surcharges if parcels exceed courier size thresholds
- Dissatisfied customers who feel they received excessive packaging
Quick fixes
- Measure before you tape. A £2 digital calliper or ruler at each station costs far less than one misrated parcel.
- Introduce a proper carton size range. Most e-commerce packing areas need five or six standard box sizes, not just two.
- Consider on-demand box cutters or auto-sizing machines if you have a wide SKU range. These tools trim excess void space in seconds and usually pay for themselves within a year.
Benchmark: If your average DIM weight ÷ actual weight ratio exceeds 1.3, you’re almost certainly paying to ship air.
2. Weak Internal Protection: Saving Pennies, Losing Pounds
The problem
Using newspaper scraps or loosely crumpled kraft paper often leaves products rattling around. Incident data shows that 22% of damage claims cite “insufficient void fill” as the primary cause.
Cost impact
- Replacements and return shipping
- Negative reviews that impact future sales
- Insurance excesses on damage claims
Quick fixes
- Use proper cushioning such as bubble wrap, moulded pulp, or inflatable airbags, each has a defined “drop height” tolerance.
- Do the shake test. If anything moves before sealing the parcel, it needs more protection.
- Standardise fill levels. Document how many wraps or pads are used for each SKU type so that temps and new staff don’t have to guess.
Remember: Your goal is to deliver once, not twice. Spending an extra 30p on bubble wrap beats sending out an £8 replacement every time.
3. Missing Lithium Battery Labels: An Administrative Time Bomb
The problem
Anything containing a lithium cell (power banks, e-bikes, smartwatches) requires a UN3481 label and, in many cases, a shipper’s declaration. Skipping the label can result in average delays of 48 hours and a £12 manual handling fee, while your parcel waits in a customs cage.
Cost impact
- Failed delivery SLAs (and potential de-ranking on marketplaces)
- Storage charges at transit hubs
- Fines for repeat offences
Quick fixes
- Keep UN3481 labels visible at all packing stations. No label, no dispatch.
- Train packing staff to recognise battery-containing products. Lithium cells are often hidden in unexpected items, Bluetooth speakers, gardening tools, and even LED decorations.
- Set automatic flags in your warehouse system so the right paperwork prints with the pick list.
If you're unsure whether your SKU qualifies, check the latest IATA Dangerous Goods Regulations - or contact our compliance desk for a quick ruling.
Putting It All Together: A 15-Minute Audit Checklist
| Task | Pass / Fail |
|---|---|
| Measure 10 random orders: is DIM weight ≤ 1.3× actual weight? | □ / □ |
| Perform a shake test on 5 high-value SKUs: any movement? | □ / □ |
| Check today’s orders for battery-powered items: all labelled UN3481? | □ / □ |
If you score a “fail” on any row, you’re losing money or customer goodwill.
Next Steps: Let Parcels2Send Optimise Your Packing Line
Our packaging experts can benchmark your current setup, model cost savings based on different box mixes, and source compliant packaging materials at scale. Most audits take less than two hours on-site and deliver an average 11% reduction in shipping costs within the first quarter.
Ready to stop overpaying?
Email info@parcels2send.com or call 00 353 89 4000 179 to book a free initial consultation.
Recent post