Right-Size Packaging: How to Cut Shipping Costs

Right-size packaging is one of the fastest ways to cut shipping costs. Carriers bill by dimensional weight, so an oversized box costs more to ship even when it is light. Fitting the box to the product saves money and material. Here is how.

What is dimensional weight?

Carriers charge based on the greater of actual weight or dimensional (volumetric) weight - a formula based on box size. A big, light box is billed as if it were heavy, so shrinking the box shrinks the cost.

How right-sizing saves money

• Lower dimensional weight - smaller boxes cost less to ship.
• Less void fill - fewer packing materials to buy.
• Fewer damages - a snug product moves less in transit.
• Less waste - lighter environmental footprint.

How to right-size

Measure the product accurately and choose the smallest box that fits with a little tolerance. See our box size guide. Mailer boxes are excellent for right-sizing - see our mailer boxes guide.

Balance size and protection

Do not undersize to the point of damage - keep enough board strength and cushioning. See our box strength guide and the complete guide to custom printed boxes.

Frequently asked questions

What is dimensional weight?

A size-based weight carriers use to price shipping; large light boxes are billed as heavier.

How much can right-sizing save?

It varies, but trimming box size and void fill often cuts shipping and material costs noticeably.

Can a box be too small?

Yes. Leave enough tolerance and cushioning so the product is protected in transit.

Ship smarter

Fit the box to the product and save. Explore our custom mailer boxes or the e-commerce boxes collection.