How to Design Mailer Boxes That Reduce Shipping Costs

Shipping rates are a significant headache for most companies. Whether you offer online or in-store sales, too high shipping rates can damage your bottom line. One solution to this issue is to create mailer boxes that minimize shipping rates.

The appropriate box design can save you money, keep products safe, and remain aesthetically pleasing to consumers. In this article, we will discuss how to design mailer boxes that save shipping costs without compromising on quality.

Why Mailer Box Design is Important for Shipping Costs

The design of a mailer box determines its dimensions, weight, and sturdiness.

All three directly influence shipping charges. An overweight or oversized box incurs a higher shipping cost, even if the item is small. Conversely, a well-made box encloses the item well and protects it. Good design keeps you from additional expense due to broken goods, returns, or lost materials.

1. Select the Proper Box Size

The secret to reducing shipping expenses is choosing the appropriate size. A box that is too large has you paying for air. Carriers frequently charge dimensional weight, rather than actual weight. Dimensional weight pricing is where the larger your box, the more you pay — even if it’s light. Measure carefully and use boxes that fit tightly. Use only enough room for necessary padding, such as bubble wrap or paper fillers.

2. Select Lightweight Yet Strong Materials

The choice of material is another consideration for lowering cost. Thick, heavy cardboard appears stronger, but it adds weight-based charges as well. Instead, opt for lightweight high-strength corrugated cardboard. Single-wall corrugated board will typically suffice for most products. Double-wall corrugated board can be used for breakables, but keep weight in check. Remember, each extra gram will increase your shipping cost.

3. Refrain from Excessive Inserts and Layers

Excess packaging layers will add weight to the box. Some companies add too many cardboard inserts, foam fragments, or excess fillers. Protection is necessary, but you must not overpack. Use only the amount of inserts required to lock in the product. Experiment with light fillers such as air pillows or crumpled kraft. You can also create custom packaging inserts from the same light cardboard to keep the product stabilized.

4. Employ Flat-Pack Designs for Storage and Shipping

If you are shipping high quantities, storage space can be an added cost consideration as well. Flat-pack mailer box designs conserve warehouse space and facilitate more efficient shipping. A flat-pack box is delivered flat and assembled only when needed. This reduces bulk in storage and can cut down on inbound freight costs from your supplier.

5. Minimize Box Height

When designing your mailer boxes, pay special attention to height. Even a few extra centimeters can push your package into a higher shipping category.

For example, a 3-inch-high box might qualify for a lower rate than a 4-inch-high box.

Maintaining a low height but keeping the product safe is a simple method of saving.

6. Try Alternative Box Shapes

Most boxes used for mailing are rectangular, but occasionally an alternative shape will be cost-saving. Long, thin boxes might be more suitable for some products and less expensive to mail. But don’t use a weird shape that can cost more to handle or ship. Try a couple of designs to determine which provides the best protection versus cost.

7. Utilize Folding Mailer Boxes for Big Stuff

When shipping large products, you may think you require a massive, heavy box.

But that is not necessarily the optimum choice. One big, bulky box consumes more space, weighs more, and usually costs more to ship. That is where folding mailer boxes can be used. A folding mailer box is made with the ability to be stored and shipped flat. When you are ready to ship your product, you fold the box into shape.

This occupies much less space in your storage and decreases the size of the shipments coming from your packaging supplier.

Why Folding Mailer Boxes Save Money

There are two primary reasons folding boxes save money:

Reduced Dimensional Weight (Volumetric Weight)

Carriers charge for shipping based on how much space your package occupies, rather than its actual weight. Folding boxes are constructed to hold products tightly, with less unused space within. This can reduce the package size to a lower-cost shipping level.

Reduced Storage and Handling Charges

A large, assembled box occupies warehouse space. Folding boxes are flat until you assemble them. This allows you to store more boxes in the same amount of space, saving on storage.

How Folding Mailer Boxes Protect Products

Others are concerned that folding boxes are not as sturdy as pre-made ones.

But contemporary folding box construction employs corrugated cardboard with tabs that lock and reinforced folds. This makes them hardy enough for heavy or delicate items, but at a minimal weight overall.

Additional custom inserts or dividers may also be added inside a folding box. These inserts support the product in its place, safeguarding it throughout transport, but at only a slight additional weight.

Examples of Large Items That Work Well in Folding Mailer Boxes

• Blankets, pillows, and other large pieces of bedding
• Flat-packed furniture components
• Large orders of clothing
• Electronic devices with inserted protective measures
• Small items are packed in clusters for a single shipment
• Additional Tips for Designing Folding Mailer Boxes
  • Select the correct board grade – Strong yet light corrugated cardboard is best.
  • Avoid oversized dimensions – Have as low a height and width as feasible.
  • Test the fold design – Make sure it is easy for workers to assemble quickly.

Use branded printing wisely – Light printing methods keep the box weight low while still promoting your brand.

By switching to folding mailer boxes for large items, you reduce both dimensional weight and material costs.

It is a smart solution for businesses that ship big products regularly but still want to keep shipping fees under control.

Choose the Right Printing Method

Printing can also indirectly impact costs. Heavy coatings or specialty inks may weigh down the box. Although small at first, added weight can accumulate with thousands of shipments. Opt for light printing processes such as digital printing for small quantities or flexographic printing for large orders.

Steer clear of non-essential heavy coatings.

Design Boxes That Fit Multiple Products

If you have various products to sell, design a universal box to hold multiple items.

This allows you to buy boxes in bulk, minimizing production costs.

It also conserves warehouse space and streamlines the packing process.

Collaborate with Your Shipping Carrier

In some cases, designing for cheaper shipping involves collaborating with your carrier.

Most carriers offer packaging recommendations to ensure you use the least expensive size and weight.

Some even have a discounted rate if you utilize their approved box sizes.

Be sure to check with your carrier prior to finalizing your mailer box design.

Utilize Eco-Friendly Lightweight Materials

Sustainable packaging not only is easier on the environment, but it can also reduce costs. Biodegradable fillers and recycled cardboard are frequently lighter than regular materials. Lightweight, eco-friendly mailer boxes reduce environmental impact as well as shipping costs.

Safeguard Products Without Overstuffing

One of the reasons companies overpack is the fear of damage. But protection does not necessarily come in the form of additional weight. Intelligent design can provide the same protection with less material. For instance, a product-specific mailer box can keep the product safe without excess filler. Inserting corner protection within the box can also help prevent damage without extra weight.

Test Your Boxes Before Full Production

Test your design with live shipping before ordering thousands of boxes. Ship test packages to various locations and observe how well they survive. Both actual weight and dimensional weight should be measured to calculate costs. Modify the design if you are able to reduce either number.

Lower Return Shipping Expenses

Good mailer box design also reduces return shipping expenses. When products are returned by customers, light and compact packaging implies less costly return shipping.

Make your boxes reusable for returns. This also saves time for customers and minimizes the amount of additional return packaging.

Reshape Branding vs. Cost

Your box must still look good for your brand. You want to achieve an attractive yet affordable design. One or two-color printing of your logo instead of full-color is possible. Branded tape or stickers will dress up your box without adding weight or expense.

Conclusion

Designing mailer boxes to minimize shipping costs is all about clever decisions.

The correct size, materials, and specifications can save you money without damaging your brand reputation.

By paying attention to weight, space, and protection, you can send products more cheaply and effectively. A well-designed mailer box is a valuable investment that translates into savings and satisfaction.

FAQs

Q1: What is the most inexpensive size for a mailer box?

It varies according to your product and shipping carrier. Smaller sizes below carrier restrictions are typically less costly.

Q2: What can I do to avoid dimensional weight charges?

Use a box that encloses the product closely, with little room for emptiness.

Q3: Are green mailer boxes more costly?

Not necessarily. Some recycled materials are lighter, which will reduce shipping costs.

Q4: Do I need single-wall or double-wall cardboard?

Single-wall is adequate for most products. Double-wall should only be used on heavy or breakable items.

Q5: Can custom box printing raise shipping charges?

Heavy ink and coatings will add a bit of weight, so use lightweight printing techniques.