Before you put anything else in that box, think how far it has traveled already. Has this box been across state lines? Has it spent some days in the rain? Does it bear a label that tells someone else something you did not intend to tell them? Each shipping box needs a quick once-over before you reuse it. Your goal is not to extend the life of each individual box forever – your goal is to find a way to utilize a shipping box as long as it suits the job.

First, take a look at every single sticker on the outside of the box. Remove any old address labels (even if they are covered by newer labels), remove any old barcodes, pull off any old tape, and remove any route stickers. While covering up half of an old barcode might seem like enough to avoid getting caught by a scanner, USPS requires that any previous markings be completely removed, either physically or completely obscured with additional labeling. Any words or symbols related to alcohol, cleaning products, batteries, etc., which could potentially delay the delivery or cause the package to be returned can also be detrimental.

After removing everything from the outside, evaluate all six sides of the box. Try pressing down on both the wider panels. Use your fingers to feel along the edges of the box checking the seams. If there is a tear, hole, water stain, extreme dent, separated panel, missing flap, etc., pass on the box. A box looks great even though its fold lines have become weak over time. While age certainly plays a role in determining whether or not to reuse a shipping box, it is just as important to consider the overall condition of the box.

Consider what type of items you plan to place in the shipping box. For example, a shipping box previously used for light orders such as t-shirts may be fine for another light order. However, it would likely not be the best option for a heavy shipment of tools, parts, or shipments containing fragile items that cannot withstand rough travel. Never use a box that contains oil, dust, crumbs, or a powerful scent. Using an existing box should always maintain the cleanliness and quality of a new shipment.

Once you have evaluated the box and determined that it is suitable for reuse, then fold it neatly into a square shape and apply new shipping tape to all major seams. As stated above, never rely on tape applied during a previous shipment. Make sure to attach the new shipping label directly onto one of the flat faces and make sure that it is centered so that it doesn’t overlap with any seams or edges. Also verify that the printing is black and that the barcode is free of wrinkles or damage. To further ensure that if the shipping label tears away from the box that you can identify which was sent using an inner address card placed within the box.

Establish a procedure for your packers to follow by designating separate areas of your warehouse for “boxes awaiting inspection” versus those that have passed inspection. You can also designate an area on an interior flap of a box to indicate who inspected the box and when. There should not be a predetermined number of uses per box. Wear varies greatly depending upon usage and therefore let the current condition of each box determine its next course of action.

Using reusable packaging materials can reduce waste and conserve resources as well as keep usable materials out of landfills. Once you’ve determined that a particular shipping box failed inspection, please recycle it where possible under applicable local regulations. Reuse is responsible stewardship – not a competition to see how many times you can use a box.