When it comes to shipping and logistics, packaging can make or break the customer experience (and your bottom line). From damaged goods to excessive waste, even small missteps in packaging can lead to costly returns, frustrated customers, and a tarnished brand reputation.
Whether you're a small business scaling up or an established company refining your fulfillment process, knowing what to avoid is just as important as knowing what to do. In this post, we’ll break down some of the most common packaging mistakes and explain how to avoid them.
Using too much or too little packaging doesn’t just affect the unboxing experience, it can create a range of problems for your business and your customers. Here's how.
It might seem safer to overload your packages with extra product wrap or void fill to protect against damage. And yes, you might prevent breakage, but that protection comes at a cost. Excess materials increase shipping expenses and supply costs, especially if you’re shipping at high volume.
Overpacking also creates environmental waste, particularly if the materials aren’t recyclable or compostable. Non-sustainable packaging often ends up in landfills, where it can take decades to decompose, leaving behind microplastics and environmental harm.
Another form of overpacking is simply using the wrong box. Oversized boxes require more cushioning to fill the space, which means more material waste and potentially higher dimensional shipping costs. In many cases, a protective mailer would be more appropriate, especially for smaller, fragile items like jewelry, electronics, or medical components. Switching to mailers where appropriate can significantly cut both packaging and shipping costs, especially if you’re billed by size rather than weight.
Some businesses also waste material by choosing low-quality packaging materials that compress during transit. That’s why many turn to HexcelPack® products for a better solution.
HexaFil™, for example, retains its shape and never flattens out. It’s available for use with both manual and automated dispensers, and pairs perfectly with HexcelWrap®. Both products can be used on their own or together, with HexcelWrap serving as the product wrap and HexaFil as the void fill.
Using too little cushioning can be just as problematic. Without enough protective packaging, products shift, collide, and wear against each other in transit. That leads to breakage, cosmetic damage, and a poor unboxing experience.
How can you tell if you’re underpacking? Look at your return rate. Frequent complaints about damaged or worn items, loose contents, or product leakage are red flags. These issues often lead to:
Finding the right balance is key. Paper-based packaging materials like HexcelWrap and HexaFil make it easier to achieve optimal protection without overpacking.
Packaging goes beyond individual boxes. If your business stores or ships items in bulk, how you wrap your pallets plays a major role in product protection and workplace safety. Incorrect or inconsistent pallet wrapping is a packaging mistake that can have wide-reaching effects.
Wrapping pallets correctly does more than just keep things organized. It also helps:
But when pallets are poorly wrapped, you risk losing all of those benefits. Poor wrapping or the wrong material can lead to instability, wasted wrap, or damaged goods before they even reach their destination.
Pallet wrapping requires both the right material and the right application. That’s where HexcelPack’s HexcelStretch™ comes in. This 100% paper-based pallet wrap is designed as a high-performance alternative to plastic wrap, offering:
If you’re shipping in bulk, improving your pallet wrapping process is one of the simplest ways to boost efficiency and reduce damage throughout your supply chain.
Selecting the right void fill or product wrap is only part of the equation. How you dispense it matters just as much, and your company may be using the wrong method without realizing it.
While you might think automated dispensing is the most efficient option, it's not always the best fit for your business. In fact, many of our customers prefer manual dispensers for their reliability, simplicity, and long-term cost savings.
Manual dispensing offer several benefits, including:
For example, HexcelPack’s manual dispensers are trusted by businesses that value simplicity, durability, and flexibility. These systems provide consistent, high-performance protection without the need for programming or power.
So, while automation has its place in large-scale operations, manual dispensers are often the more practical and cost-effective choice, especially when reliability, ease of use, and portability are top priorities.
Automated dispensers are designed to streamline the packaging process, especially in busy fulfillment environments where time and consistency are critical.
Key benefits include:
HexcelPack’s AutoHexaFil™ is built for speed and precision. With programmable controls, packers can select and dispense the ideal length of void fill for each type of shipment. The system keeps material flow consistent.
A common packaging mistake businesses make is overlooking the sustainability of their materials. This can lead to two major issues: environmental harm and a disconnect with consumer expectations.
For years, many companies used whatever materials were readily available, often resorting to plastic bubble or styrofoam peanuts. But these materials are harmful to the environment and increasingly out of touch with modern packaging standards.
Plastic and other synthetic options can take decades to decompose, and they’re usually not curbside recyclable. This means customers have to go out of their way to dispose of them properly. Because of this, they often end up in landfills where they don’t belong, contributing to long-term waste.
Today, more sustainable packaging options exist, like those from HexcelPack, that are:
Sustainable packaging isn't just good for the environment, it’s also good business. Today’s consumers are more eco-conscious than ever. Many actively seek out brands that use environmentally-friendly packaging and are even willing to pay more for it.
Beyond individual preferences, broader regulatory trends are shaping the future of packaging. For example, the European Union is moving toward stricter rules that will phase out unsustainable packaging altogether. Businesses that plan ahead can not only stay compliant but gain a competitive advantage.
Unsure whether your packaging process is as efficient and effective as it could be? HexcelPack is here to help. Our team can evaluate your current setup—from materials to methods—to identify opportunities to reduce waste, improve product protection, and streamline your operation.
We’ll also recommend sustainable packaging solutions that not only perform better but align with your brand values and customer expectations.
Ready to optimize your packaging? Contact us today to start the conversation.