Essential Packaging Design Mistakes to Avoid (And What to Do Instead)

Your product packaging is its introduction—and perhaps your only opportunity to capture a customer’s attention in-store or online. Fantastic packaging design isn’t merely pretty pictures; it’s a tactical asset that conveys worth, encourages brand trust, provides protection, and makes people buy.

However, millions of brands—particularly small businesses or startups—fall prey to preventable packaging design errors, which result in:

Lost sales
Bad customer reviews
Damage or returns of the product
Penalties for non-compliance
Negative brand image

This article details the most prevalent packaging design errors and provides you with real-world, actionable tips on how to avoid them.

Error #1: Putting Form Before Function

The Problem:

Most brands spend too much attention on looks and forget about the functional element of packaging. A gorgeous box that is difficult to open or won’t keep the product safe leaves customers infuriated.

What to Do Instead:

Design with both form and function:

Test packaging for durability, particularly in shipping
Apply easy-open tabs or perforated tear strips
Take into consideration the fragility, shape, and weight of the product
Consider storage and shelf influence

Form is not the enemy of function—the most effective packaging harmonizes both.

Error #2: Selecting an Inappropriate Material

The Issue:

Poor-quality or incompatible materials can trash both the product and customer image. Breakable items in lightweight boxes? Meltable products in non-insulated bags? Unwashed hands waiting to strike.

What to Replace It With:

Choose materials based on:

Product type (glass, food, electronics, cosmetics, etc.)
Shipping and logistics methods
Sustainability targets
Sensitivity to temperature or humidity

Refer to packaging suppliers for advice on industry-standard materials like:

Corrugated kraft for delicate products
Barrier films for perishables
Airless pumps for skincare
Recyclable rigid boxes for high-end products

The appropriate material upscales the product experience and brand reputation.

Error #3: Overdesigning the Packaging

The Issue:

There is too much text, color, icon, and clutter that clutters the packaging. It is particularly an issue for e-commerce, where customers base decisions on swift visual observations.

What to Do Instead:

Practice visual hierarchy and design minimalism:

Take advantage of whitespace to highlight design elements
Emphasize one main message (product benefit or feature)
Limit 2–3 colors maximum
Avoid extraneous decorative fonts or patterns

Simplicity sells—clean designs build trust and a premium feel.

Mistake #4: Disregarding Brand Consistency

The Problem:

Having varying fonts, colors, or logos on packaging vs. on your website, social media, or storefront confuses and waters down brand identity.

What to Do Instead:

Create a distinct brand style guide and adhere to it throughout:

Packaging
Labels and inserts
E-commerce photography
Email marketing and advertising

This encompasses:

Logo positioning
Foot hierarchy
Color range
Tone of voice

Consistency creates recognition, and recognition creates trust.

Error #5: Employing Illegible Fonts and Bad Typography

The Problem:

Employing too stylized fonts or bad contrast will make your label hard to read. This is most aggravating for critical information such as ingredients, sizes, or directions.

What to Do Instead:

Use clear, legible fonts (sans serif for body copy)
Provide contrast between text and background
Do not use font sizes below 8pt for printed material
Bold, italic, and space to emphasize, not decorate

Typography is not decoration—it’s communication.

Error #6: Inadequate or Ambiguous Product Messaging

The Issue:

Customers shouldn’t be left to wonder what your product does, for whom it’s suitable, or why they should purchase it. Vague, technical, or incomplete messaging equals lost sales.

What to Do Instead:

Develop a concise brand narrative and product USP (unique selling proposition):

What is the product?
For whom is it suitable?
What are the benefits?
How does it differ?

Employ succinct, compelling copy and emphasize primary selling points on the front panel of your package.

Error #7: Not Meeting Regulatory Specifications

The Issue:

Lack of mandatory information—such as nutritional facts, barcodes, batch numbers, or allergens—can result in fines, recalls, or a loss of shelf availability in stores.

What To Do Instead:

Look up industry regulations before designing:

Food & drink: Nutritional labeling, allergen information, country of origin
Cosmetics: Ingredient declaration, batch number, expiration
Medical: UDI code, manufacturer information, warnings
Electronics: CE marking, RoHS, recycling symbols

Collaborate with legal or regulatory advisers to comply with the country or region.

Error #8: Forgetting the Unboxing Experience

The Problem:

Brands have their sights on the outside and ignore the inside experience. Bland, unengaging, and transactional is how a generic unboxing feels.

What to Do Instead:

Employ inside-the-box branding to generate delight:

Banded tissue paper, thank-you notes, and inserts
Surprise bonuses or samples
QR codes for user manuals or story vids
Clutter-free layout for visual pleasure

Make unboxing Instagram-worthy to drive user-generated content and word-of-mouth marketing.

10. Mistake #9: Forgetting Sustainability

The Problem:

Too much plastic, non-recyclable foam, or too-large boxes annoy green-conscious consumers and may cause backlash for the brand.

What to Do Instead:

Choose sustainable and environmentally friendly packaging:

FSC-certified or recycled paper
Compostable mailers
Minimal coating and ink
Green plant-based plastics
Gusseted reusable containers

And share your sustainability initiatives on the package. Transparency is what customers adore.

Example:

Made from 100% recycled fibers and is 100% recyclable. One tree is planted for every 50 cases shipped.”

Error #10: Inadequate Print Quality and Production Failures

The Issue:

Faded or crooked colors, pixelated photos, or peeling labels immediately give your product a cheap look, even when it’s not.

What to Do Instead:

Take high-res files for all graphics (min. 300 DPI)
Order press proofs or electronic samples before full runs
Work with seasoned, professional printers
Verify bleed areas, safe zones, and alignment in die-lines

Your packaging reflects your product quality. Don’t compromise here.

Final Thoughts: Good Design Is a Competitive Advantage

Great packaging doesn’t merely package a product—it sells it, communicates its story, and develops brand loyalty. By avoiding these ten frequent packaging design errors, you can develop a brand experience that: