Packaging Mistakes That Lead to Damaged Deliveries (And How to Avoid Them)

Every parcel that leaves your business is a reflection of your brand. So, when customers receive packages that are crushed, torn, or arrive with broken contents, it not only leads to returns and refunds - it erodes trust.

Shipping damage costs UK retailers millions every year, and in most cases, the issue isn’t the courier - it’s the packaging. At Parcelsend UK, we’ve seen it all. Here are the top packaging mistakes that lead to damaged deliveries, and how your business can avoid them.

1. Using the Wrong Size Packaging

The first common mistake that many retailers make is using packaging that is too large or too small for the product being shipped. Oversized boxes leave empty space for product movement and undersized boxes can compress items or simply not fit the item its intended for.

How to avoid

• Measure your item before purchasing your packaging so you have an idea of what size box or mailer you need to use.
• Choose packaging that leaves a 2–5 cm gap around the item for void fill.
• For smaller or flatter items, use snug-fit padded mailers.
• For delicate goods, use internal supports like corner protectors or inserts.

2. Not Using Adequate Internal Protection (Void Fill)

The next common mistake is sending products in boxes with little to no padding or internal support. If a box has no internal protection, what will protect your items from moving about. Even a sturdy box will cause items to slide or hit the sides with no protection and internal movement is one of the leading causes of surface damage, scratches, and breakages.

How to avoid

• Wrap items with bubble wrap, Hivewrap, or kraft paper.
• Fill remaining void space with paper void fill, eco chips, or air cushions to cushion and secure your items.
• For fragile or high-value items, double-boxing with padding between layers adds extra protection.

3. Reusing Damaged or Weak Boxes

Despite recycling your old boxes may seem more economical, recycling boxes that are worn, creased, or previously taped over can often cause more harm. Worn flaps may not seal properly, increasing the chance of it opening in transit and structural integrity is compromised, leaving the box more vulnerable to crushing or splitting.

How to avoid

• Always use new or high-quality double walled boxes for anything over 2kg or delicate in nature.
• If reusing boxes, inspect them thoroughly and reinforce weak areas with strong packing tape.

4. Using the Wrong Type of Tape or Poor Sealing

Using low-quality, cheap tape, masking tape, or only sealing the centre seam of a box is not the right way to tape your packaging. Poor sealing often results in boxes or bags popping open during transit. Rain water or humidity will also weaken cheaper tape.

How to avoid

• Use quality packing tape at least 48mm wide. View our range of packaging tape here.
• Apply the H-taping method: seal the top and bottom seams, and both side flaps.
• For heavier boxes, consider using reinforced gummed tape.

5. Ignoring Weather Resistance

Never ignore the weather! Sending mail in packaging that isn’t water-resistant or weather-protected will end up in damaged goods. Rain, snow, or damp warehouse environments can damage paper-based packaging or contents inside if not protected properly.

How to avoid

• Use mailing bags, padded mailers, or add internal plastic sleeves for documents, clothing or books.
• Seal boxes well with waterproof tape, and consider moisture-resistant outer liners for sensitive goods.

6. Skipping “Fragile” or Handling Labels

sending items that are fragile or delicate? Tell the courier. Not labelling your packages that need careful handling will result in breakages. Couriers rely on clear visual cues to know whether a parcel should be stacked, turned, or handled with care.

How to avoid

• Use "FRAGILE", “This Way Up”, or “Do Not Bend” stickers or tape where relevant. View our range of warning tapes here and view our range of warning labels here.
• For oddly shaped or delicate goods, consider custom labels or printed tape for higher visibility.
• Ensure bubble wrap is used around delicate items for added protection.

7. Overloading Boxes or Mailers

The final packaging mistake many retailers make is stuffing too many items into one package or exceeding the weight capacity of the box. When this occurs, it causes boxes or mailers to split or burst open. Padded mailers can tear if the contents are sharp or bulky.

How to avoid

• Know your box’s maximum weight capacity — heavier doesn’t always mean stronger.
• Use multiple boxes and split orders when necessary.
• Use rigid mailers or small boxes instead of overstuffed envelopes.

Conclusion: Pack with Purpose, Deliver with Confidence

Shipping damage is avoidable, and by choosing the right materials, sealing properly, and avoiding common pitfalls, you can dramatically reduce returns and boost customer satisfaction.

Here at Parcelsend UK, we can offer you a wide range of high-quality packaging supplies that are perfect for safe and secure shipping and will meet all your shipping needs. Contact us today to learn more about our packaging solutions and find the best option for your business.