Everything an E-Commerce Business Needs to Know About Packaging

Jul 3

In this guide, we’ll break down everything you need to know about e-commerce packaging. Whether you’re shipping apparel, electronics, glassware, or anything in between. We’ll talk through choosing the right box strength (including board grades, ECT and burst ratings), selecting the ideal box size and style, and picking the best tape for secure sealing (acrylic, hot-melt, or water-activated). We’ll also cover the most effective dunnage options—like air pillows, paper, foam, and bubble wrap—as well as labeling best practices and carrier compliance tips to keep your shipments moving smoothly.

Finally, we explore sustainable packaging strategies that reduce waste, lower costs, and appeal to eco-conscious customers. This guide is built for small business owners, fulfillment teams, and growing brands who want to ship smarter—every time.

Box Strength: Board Grades, ECT & Burst Ratings

When it comes to protecting your product in transit, box strength matters—and it starts with understanding how corrugated boxes are built and rated.

Corrugated boxes are made from layers of linerboard and fluted paper. The number of layers defines the board grade:

Single-wall has one layer of fluting (standard for most retail shipments),
Double-wall has two layers of fluting (for heavier or more fragile products)
Triple-wall has three layers of flutihng (mostly used in industrial applications)

Flute types (A, B, C, E, F) also play a role, each offering different thickness and cushioning characteristics. C-flute is the most common for shipping boxes due to its balance of strength and crush resistance.

How Box Strength is Measured: ECT vs. Mullen Test

There are two main tests used to measure the strength of corrugated boxes:

Edge Crush Test (ECT): Measures the pressure a box can withstand before being crushed on its edge (important for stacking). Common ratings include 32 ECT and 44 ECT. The higher the number, the stronger the box is when stacked.
Mullen Test (Burst Strength): Measures how much internal pressure (in psi) the box can endure before it bursts. A box labeled 200# can withstand 200 pounds per square inch of pressure—ideal for protecting against punctures and rough handling.

Pro tip:

ECT = stacking strength

Burst strength = puncture/impact resistance

Major carriers like UPS and FedEx even weigh in by recommending a minimum of 32 ECT or 200# burst strength for ground shipments. Anything less can risk rejection, damage claims, or additional fees.

Choosing the Right Box for Your Shipment

Your choice of board grade should align with product weight, fragility, and shipping conditions:

For lightweight, non-fragile items like clothing or packaged snacks, a 32 ECT single-wall box is usually sufficient.
For heavier or more delicate items like ceramics, glassware, or electronics, opt for 44 ECT or 275# double-wall to withstand stacking and shock.
Products shipped in bulk or internationally may require triple-wall or reinforced corrugated to meet export requirements and prevent damage.

Also consider the distribution of weight inside the box. Center-heavy items should be packed with care and supported with thicker board or internal bracing.

Keep in mind: stronger boxes use more material, which means higher cost and a larger environmental footprint. Right-sizing your packaging to balance protection and efficiency is key—both for your budget and your sustainability goals.

Choosing Box Size and Type

Selecting the right box size and style improves protection and reduces waste. The most common box style is the RSC (Regular Slotted Container). An RSC is cut from one corrugated sheet with four top/bottom flaps: the outer flaps (often C-flute) and the inner flaps. RSCs are easy to assemble and tape, and suit a wide range of products (consumer goods, electronics, appliances, etc.). They’re usually recyclable and cost-effective.

Beyond RSC boxes, there are specialty styles:

Die-cut boxes (custom shapes with tabs or handles) fit specific products snugly. They are often a fold-and-lock design, ideal for high-end or oddly-shaped items (e.g. cosmetics, gift boxes).
Mailers (Poly, Bubble, Kraft): Lightweight padded envelopes or pouches (polyethylene plastic or kraft with padding) for non-fragile items like clothing. Poly mailers are, slim, and self-sealing. Bubble mailers add a layer of air bubbles for small fragile items (jewelry, books). Mailers save weight and bulk—no need for large void-fill—so they generally result in lower costs.
Corrugated mailers or padded boxes: One-piece corrugated mailers (ship-flats) that fold into a rigid envelope, or rigid padded boxes (cardboard lined with foam or paper) for glasses, bottles, or gifts. These combine moderate protection with lighter weight than a full box.

Right-sizing tips: Always use the smallest box that fits the product plus its protection. Excess empty space means more filler and wasted material. For example, if you ship a single mug, a snug 8×8×6″ box with a bit of paper cushion is better than a 16×12×12″ box full of void. Custom-fit boxes can help eliminate void. At the end of the day, minimizing space will reduce materials and also shipping weight (and thus carbon footprint).

Tape Selection: Acrylic vs. Hot-Melt vs. Water-Activated

Choosing the right carton-sealing tape is another critical part of the total package. The three most common tapes are acrylic, hot-melt, and water-activated (gummed) tape. Each has distinct properties and purpose:

Acrylic (Polypropylene) Tape: A clear or tan plastic tape with a water-based acrylic adhesive. It’s the most common choice. Acrylic tape adheres moderately well to corrugated board, resists UV light (won’t yellow) and holds up in cold or humid conditions. Once applied, acrylic tape will increase adhesion. This tape is easy to use (only a tape gun is needed) and is ideal for small to medium sized packages, and is fit for most environments. Drawback: It has lower initial tack and tensile strength than hot-melt, so it’s not the best for very heavy boxes or rough handling.
Hot-Melt Tape: A plastic film tape coated with a synthetic rubber adhesive. Hot-melt tape grabs aggressively on contact, providing a very strong quick adhesion and high tear resistance. It seals quickly, even on recycled or rough corrugate, and is favored for heavy or tall stacks of boxes. Drawback: The rubber adhesive is sensitive to temperature extremes—it can soften in heat or become brittle in cold. It also tends to yellow over time. Hot-melt’s high initial tack makes it ideal for automatic tape dispensers or when rapid bonding is needed.
Water-Activated (Gummed) Tape: A kraft paper tape that is moistened to activate a water-soluble adhesive. When applied, it bonds into the corrugated liner for a very durable seal. It’s tamper-evident and excellent for high-security or very heavy shipments. Drawbacks: You need a dispenser and water to moisten it, so it’s less convenient for low volumes. Also, it won’t stick to dusty or dirty surfaces.

Pro Tip: Match tape grade to box strength. Thicker boxes or heavier contents call for higher-strength tape (usually hot-melt or gummed). For everyday packages, a good-quality 2–3″ acrylic carton tape usually suffices. Always inspect the seal after taping, and consider “H-taping” the top and bottom of the box for extra security on heavy shipments.

Dunnage (Void Fill) Options and Uses

Dunnage refers to the cushioning or void-fill materials used inside boxes to prevent movement and absorb shock. Common options include:

Kraft Paper (Void Fill/Crinkle): Layers or crumpled kraft paper (often made from recycled paper) are stuffed around items. It’s cheap, recyclable, and offers good protection against scratches. Kraft void fill is eco-friendly and pairs well with bubble wrap or foam for maximum protection.
Air Pillows (Inflatable Cushions): Plastic bags inflated with air or recycled gas. Air pillows are lightweight, low-cost fillers that fill empty space without adding much weight. They are easy to dispense (often from an on-demand machine) and work for almost any package. Use them to secure multiple items or large voids, but ensure they don’t pop during shipping. Enough air pillows should be used to create a slight crown on the top of the box. This ensures maximum void fill, and provides outward pressure on the tape, creating a strong seal or closure.
Bubble Wrap: Sheets of plastic bubbles that cushion items individually. Great for wrapping fragile items (glassware, electronics, mirrors) or lining box walls. Bubble wrap conforms to shapes and resists pressure. Downsides: it’s not easily recyclable (unless specifically marked), but it’s lightweight and reusable.
Foam Sheets / Inserts: Flat foam sheets (polyethylene or polyurethane) or pre-cut foam shapes can pad items and fill gaps. Foam is excellent at absorbing shock and vibration, and can be custom-cut or molded for sensitive products (e.g. electronics, medical devices). Some mailers even have built-in foam lining. Foam (if non-recycled) is not biodegradable, so reuse or use only where needed.
Packing Peanuts (Loose Fill): Polystyrene or starch-based loose pellets that “flow” around items, filling any irregular void. Traditional foam peanuts are cheap and reusable, but they generate static and are hard to compress tightly. Biodegradable (starch) peanuts exist and dissolve in water, offering an eco-friendlier option. Note: Don’t use peanuts with sensitive electronics (static risk).
Molded Pulp / Inserts: Custom-shaped trays or partitions made from recycled paper pulp (like egg cartons or wine shippers). These are fully recyclable and fit products precisely (bottles, hardware, glass). They provide excellent cushioning for delicate shapes and are widely used for electronics or glass items.
Corrugated and Honeycomb Inserts: Thick cardboard inserts or honeycomb-shaped panels used for blocking/bracing. They are very strong and can be cut into strips for edge protection or spacers. Honeycomb board (paper cells bonded between liners) is lightweight yet stiff, great for heavy loads. Both options are recyclable and reusable.

Use Cases (Examples): For a bottle of wine, a molded pulp insert or corrugated divider is ideal. For a t-shirt, kraft paper and a poly mailer suffice. For mixed items in a box, combine crumpled paper and a couple of air pillows to keep everything tight. Always ensure the item cannot shift by shaking the box: if you hear movement, add more filler. Proper dunnage reduces damage returns and boosts customer satisfaction.

Labeling Best Practices and Shipping Compliance

Correct labeling ensures packages are handled right and comply with carrier rules.

Placement: Always affix the shipping label on the largest flat side of the box. Avoid seams, edges, or corners. Position the barcode and tracking number so they face outward and are not folded or creased. Cover the label with clear adhesive tape or a label pouch to protect it from moisture or abrasion. Ensure the package surface is clean and dry before labeling to avoid peeling.

Clarity: Print labels at high resolution. Barcodes should scan easily – avoid printing blurs or using fine text. Keep label information (addresses, tracking code, handling symbols) large and legible. Do not cover the barcode or address with tape seams or extra stickers.

Content & Compliance: Include both sender and recipient addresses, a return address, and any required service markings (e.g. “Fragile,” “This Way Up” arrows if needed). Check carrier-specific requirements: for example, USPS, UPS, FedEx have label size and format guidelines. For international shipments, attach customs forms and any required hazard labels (e.g. lithium battery warnings). Tip: Many carriers (and Amazon FBA) provide free label printers or templates – use them to ensure correct barcode placement and size.

Quality Checks: Before sending, verify every label. Common mistakes include illegible printing, wrong addresses, or reuse of old labels. Dispose of misprinted labels—do not recycle or stick them on the box. Train staff on a consistent labeling procedure: clean application, flat and visible, no overlap. This minimizes delays and lost packages. By following label best practices and carrier rules, you streamline delivery and reduce risk of fines or returns.

Sustainability in Packaging

Eco-friendly packaging is increasingly important. The good news is corrugated and paper solutions are both effective and green. Corrugated cardboard is typically made from recycled content and is 100% recyclable. When possible, choose boxes and mailers made from post-consumer recycled fiber (many suppliers offer such options). Use paper tapes or water-activated tapes (often kraft paper) which can be recycled or composted with the box.

Reduce Plastic & Single-Use Waste: Replace plastic void-fill with paper (kraft sheets, paper pillows). Swap plastic poly mailers for compostable mailers or cotton totes when feasible. For fragile wraps, consider paper-based bubble alternatives (e.g. paper bubble wrap) or corn-starch peanuts.
Right-Size to Reduce Footprint: Using oversized packaging wastes material and increases shipping weight. By right-sizing (using a box just large enough for the item plus cushioning), you cut raw material use and decrease shipment weight. This directly lowers carbon emissions from transportation: smaller, lighter packages require less fuel. Automated packing systems or custom box on demand can help optimize size.
Biodegradable Options: Use compostable or biodegradable materials where possible. Examples include compostable air pillows, starch-based packing peanuts (they dissolve in water), and molded pulp inserts. These materials break down naturally and reduce landfill waste. Encourage customers to reuse or recycle the packaging (e.g. printing “We use recycled boxes!” on the label).
Sustainable Printing: Choose eco-friendly inks (soy- or water-based) for any printed packaging to minimize toxins. Use minimalistic design to reduce ink usage. Print labels on recyclable paper instead of plastic stickers.

Conclusion

Great packaging does more than protect products—it protects your brand, your margins, and your customer experience. From box strength and tape to dunnage, labeling, and sustainability, every decision matters.

Whether you’re shipping daily or just getting started, packaging smarter is one of the easiest ways to improve efficiency and build customer trust.

Need help optimizing your packaging strategy?

Rogue Fulfillment