Finding the right box seems like an easy decision when shipping, but selecting the wrong one could cause you a lot of problems before you ever get the item to the truck. Using a box that is larger than what you actually have to pack will require additional filler material; will take longer to pack; and possibly increase the cost of the shipping rate. Conversely, if you select a box that is too small (or “too tight”) for the item, it could apply pressure to the item itself and there would be limited room for the addition of protective materials. So your job is not to pick the largest box available. Your job is to determine which box provides the best fit.

First measure the dimensions of the item(s) you plan to ship. Take into consideration whether the item has a handle, lid, or any protruding parts. Then add any needed space for the type of padding the item requires. For example, a soft t-shirt might only need a little bit of room around it to protect it during shipment. However, a glass jar may require enough room to wrap safely, and possibly a different kind of protective cushioning. After determining how much space you need around each item based on their individual requirements, begin looking at various types of cardboard boxes to find one that fits those measurements.

You cannot assume that an item’s weight is directly related to its size. For instance, a small metal part may weigh considerably more than a large stuffed animal. Therefore, do not base your assessment of an item’s strength solely upon its appearance. Instead check the weight limit indicated on the bottom of the box when it is shown. Lightweight items generally will do fine in standard single-walled boxes. Items that are heavy, sharp or fragile, however, may necessitate the use of boxes made from thicker materials or using two separate boxes for added support.

Once you have found a suitable box, test its ability to hold the item securely by placing a layer of protective material on the bottom of the box, setting the item in place and then adding padding around all sides until no gaps remain. Shake the box gently. If the item does not budge, the box should be able to withstand normal shipping conditions. Additionally, if shaking the box causes the sides of the box to sag or appear strained, do not attempt to secure them with excessive amounts of tape. Instead go back and look for a better size.

In some cases, the shape of an item can provide guidance as to which type of box would work best. For example, long objects tend to fit best within narrow cartons; flat items work best within short boxes and multiple smaller items can be safest when divided up with dividers. Maintaining a number of commonly used sizes on hand can significantly reduce the amount of time spent packaging each day without having to purchase and store unused inventory in excess quantities.

Finally, before purchasing a large quantity of boxes, try packaging one sample and weighing it both with and without the added weight of filler and tape. This one-time experiment may reveal a weakness in the construction of a particular wall or identify an area where corners are too tightly confined prior to making the same mistakes for numerous shipments.

Choosing an appropriately sized box can benefit not only the contents inside but also the customer receiving the package. By minimizing excess packaging materials, saving storage space and reducing waste sent to landfills, you also create an attractive, clean and easily opened package that can be recycled.