Pack professionally, safely, and sustainably with the right shipping materials

When your customers receive their order in an intact and professional-looking package, you not only create a strong first impression—you also reliably protect your goods and provide clear proof of their intact condition. In addition, secure packaging is significantly more sustainable. The CO₂ footprint of a damaged, repacked, and re-shipped parcel is dramatically higher than simply packing it safely once—even if that requires more packaging material. Proper packaging pays off in several ways.

Körber’s State of Shipping & Returns 2023 survey confirms this: 85% of respondents stated that parcel presentation is important. According to them, responsibility for the parcel interior (61%) and exterior (23%) lies at least partly with the seller. In fact, 30% said poor packaging negatively influences their opinion of the seller, while 24% said visible outer damage does the same. So following the principle “prevention is better than cure” is worthwhile—because better packaging also protects against rough transport conditions.

If a parcel is damaged during transport, delays may occur because it must be removed from the process and made transport-ready again. This is always a “quick fix” and not necessarily a secure packaging solution. Long delivery times, visible packaging damage, and possibly even damaged goods can all result in avoidable returns. Insufficient packaging can also lead to additional costs: if transport containers, sorting systems, or other shipments are damaged, liability rests with the sender of the defective parcel.

There are many good reasons to pack a parcel securely and professionally:

• Fulfilling customer expectations
• Avoiding transport delays
  - Liability protection in case of damage
  - Preventing loss of reputation or customers
• Reducing return rates

Parcel networks today are highly automated to deliver large volumes in the shortest possible time. During transport, parcels may experience significant strain. When stacking parcels, heavy packages may be placed on lighter ones. Parcels may also be hit by others weighing up to 31.5 kg. Temperature fluctuations present another challenge: depending on the route, a parcel may face extreme heat or cold for several hours — between -10°C and +60°C.

To make sure your goods arrive exactly as you sent them, here are the pros’ tips. These three steps will help you optimally prepare your shipment for transport:

1. Outer Packaging

Boxes used for storage typically do not meet shipping requirements. Safe options include sturdy corrugated cardboard boxes without slots or handles. For items weighing more than 5 kg, we recommend double-wall corrugated boxes. Choose a size that fits the product plus any inner packaging, leaving some room. Fill empty spaces with cushioning material. The longer the transport route and the more fragile the goods, the stronger the packaging should be.

Note: If products are touching the outer walls, the box is too small.

2. Inner Packaging

The product should be cushioned on all six sides (sides, top, and bottom). Suitable options include molded padding, air cushions, or loose fill. If you’re not using molded padding, wrap the goods in multiple layers of bubble wrap, corrugated paper, or kraft paper. The heavier and more sensitive the contents, the more cushioning is needed.

Tip: Place heavy items at the bottom, light ones on top, and highly sensitive ones in the center. If shipping multiple items, ensure they don’t touch each other.

3. Sealing

The best options are plastic tape or fiber-reinforced paper tape. Both have strong adhesion and high tear resistance. When using paper tape, look for parallel fiber structures combined with S-patterns, or grid reinforcement for heavier loads. Tape should be at least 50 mm wide and extend over the edges. Intact tape serves as proof that the shipment hasn’t been tampered with.

Tip: The heavier the goods, the stronger the seal and the more taping required.

DHL offers packaging and shipping materials that meet all requirements, including highly sustainable options. You can find all DHL packaging tips HERE at a glance.