The Shipping Damage Problem
11%
of packages damaged in transit
$1B+
annual shipping damage claims in US
25%
of returns due to damaged goods
70%
of damage is preventable with proper packing
Whether you're shipping handmade ceramics, electronic components, glassware, or antique collectibles, the principles of fragile item packaging remain the same. In this guide, we'll walk through each step of the process — from choosing the right box to sealing and labeling — so you can dramatically reduce your damage rate and protect your products (and your bottom line).
Step 1: Choose the Right Box
The box is your first line of defense, and choosing the wrong size is the single most common packing mistake. The box needs to be large enough for adequate cushioning on all six sides, but not so large that the product can shift around during transit.
The 2x Rule
As a general guideline, your outer box should be approximately twice the volume of the product it holds. This provides enough room for 2–3 inches of cushioning material on every side. For a product that measures 8" x 6" x 4", you'd want a box around 14" x 12" x 10".
Quick size formula:
Box dimension = Product dimension + (2 x cushioning thickness on each side)
Example: 8" product + (2 x 3" cushioning) = 14" box dimension
Box Selection Tips
- ●Use new or like-new boxes. Previously used boxes lose 20–40% of their compressive strength. For fragile items, this matters. If you must reuse a box, inspect it for soft spots, creases, and moisture damage.
- ●Choose at least 32 ECT or 200# Mullen. For most fragile items under 40 lbs, a standard 32 ECT single-wall box provides sufficient protection. For heavier items, step up to 40 ECT or double-wall.
- ●Avoid warped or bulging boxes. A box that doesn't sit flat has compromised structural integrity and won't stack or protect properly.
- ●Consider C-flute for cushioning. C-flute corrugated provides the best balance of cushioning and stacking strength for fragile item shipping.
Step 2: The Box-in-Box Method (For High-Value Items)
For extremely fragile or high-value items — think fine art, laboratory equipment, expensive electronics, or antiques — the box-in-box (or double-boxing) method provides the ultimate protection. This technique creates a suspension system that isolates the product from external impacts.
Wrap the product
Wrap the item in bubble wrap, foam sheeting, or acid-free tissue paper (for sensitive items). Secure with tape — not too tight, but snug.
Place in the inner box
Put the wrapped item into a snug-fitting inner box with at least 1 inch of cushioning on all sides. Seal the inner box with tape.
Cushion the outer box
Line the outer box with 3–4 inches of cushioning material on the bottom. Place the sealed inner box centered inside.
Fill all voids
Pack cushioning material around all sides and on top of the inner box. There should be no movement when you shake the outer box.
The box-in-box method effectively creates two layers of impact absorption. If the outer box is crushed, dented, or punctured, the inner box and its cushioning layer provide a second barrier of protection. This method is required by most shipping insurance policies for items valued over $500.
Step 3: Choose the Right Cushioning Material
Not all cushioning materials are created equal. Each type has specific strengths and weaknesses depending on the product, weight, fragility level, and budget.
Bubble Wrap
Most PopularAvailable in small (3/16"), medium (5/16"), and large (1/2") bubble sizes. Small bubbles work best for surface protection and wrapping items tightly. Large bubbles provide more cushioning for heavy impacts. Medium is the all-purpose choice.
Protection
8/10
Cost
$$
Eco-Friendly
3/10
Foam Packaging
PremiumIncludes polyethylene foam sheets, polyurethane foam inserts, and custom-molded foam cavities. Foam provides the highest level of protection and can be precisely cut to cradle products. Commonly used for electronics, medical devices, and precision instruments.
Protection
10/10
Cost
$$$$
Eco-Friendly
2/10
Packing Paper (Kraft)
Eco-FriendlyCrumpled kraft paper is one of the oldest and most reliable cushioning materials. It's fully recyclable, biodegradable, and surprisingly effective when used in sufficient quantities. Great for void fill and wrapping items to prevent surface scratches. Requires more material to achieve the same protection level as bubble wrap.
Protection
6/10
Cost
$
Eco-Friendly
10/10
Air Pillows
LightweightInflatable plastic pillows that are excellent for void fill. They're extremely lightweight (which saves on shipping costs) and inflate on demand, reducing storage space needs by up to 99% compared to pre-made materials. However, they provide less impact protection than bubble wrap or foam for direct contact cushioning.
Protection
5/10
Cost
$$
Eco-Friendly
4/10
Step 4: Apply the 6-Sided Protection Rule
This is the golden rule of fragile item packing: your product must have cushioning material on all six sides — top, bottom, left, right, front, and back. No exceptions. A package can be dropped or impacted from any direction, and the weakest side is where the damage will occur.
Minimum Cushioning Thickness by Product Weight
The most commonly neglected areas are the top and the bottom of the box. Many packers place cushioning on the sides but forget that the top of the box is the most likely impact point (packages are often set down roughly), and the bottom needs cushioning to absorb the constant vibration of truck and conveyor transport.
Step 5: Seal with the H-Tape Method
How you tape the box matters more than most people realize. A properly sealed box maintains its structural integrity during handling. A poorly sealed box can pop open, exposing contents to damage or loss.
The H-Tape Method
Tape type matters:
Use pressure-sensitive acrylic or hot-melt packing tape (the brown or clear stuff on a roll). Never use masking tape, duct tape, cellophane tape, or string. These do not provide adequate seal strength for shipping.
Step 6: Label Properly
Labels communicate handling instructions to every person who touches your package along the supply chain. While there's no guarantee that handlers will follow label instructions, studies show that packages with visible fragile labels experience 20–30% less rough handling.
FRAGILE
Place on at least 3 sides of the box. Use bright red or orange labels for visibility.
THIS SIDE UP
Critical for items with a specific orientation. Place arrows on all 4 sides of the box.
HANDLE WITH CARE
For glass, ceramics, and items that can't withstand vibration or impact.
Common Packing Mistakes to Avoid
Even experienced shippers make these errors. Avoiding them can cut your damage rate significantly:
Using a Box That's Too Large
An oversized box requires excessive void fill, adds shipping weight and cost, and creates more room for the product to shift. If the cushioning compresses or shifts during transit, your product ends up bouncing around inside an empty box. Size the box to allow for proper cushioning — no more, no less.
Insufficient Top Cushioning
The most neglected area in packing. Boxes are routinely stacked and dropped, and the top takes the most abuse. Always fill the space between your product and the box lid with cushioning material. If you can press down on the closed flaps and feel the product, you don't have enough material on top.
Wrapping Multiple Items Together
When packing multiple fragile items in one box, each item must be individually wrapped and separated. Items touching each other will damage each other during transit. Use cardboard dividers, individual bubble wrap wrapping, or cell-style partition inserts.
Using Newspaper as Cushioning
While newspaper is readily available, it provides minimal shock absorption and the ink can transfer to products, staining surfaces permanently. Use unprinted newsprint or kraft paper instead if you want a paper-based cushioning option.
Ignoring Temperature Considerations
Packages can experience extreme temperatures during transit — from freezing cargo holds on aircraft to 140°F+ inside delivery trucks in summer. Heat can melt foam cushioning, weaken adhesives, and damage temperature-sensitive products. For Atlanta shipments during summer months, consider insulated liners or thermal packaging for sensitive items.
The Shake Test: Your Final Check
Before you seal the box for good, perform the shake test. Pick up the sealed box and give it a firm shake in all directions. If you can feel the contents moving, shifting, or rattling inside, you need more cushioning material. The product should be completely immobilized — no movement in any direction.
You can also perform a drop test for quality assurance: seal a test package and drop it from waist height (about 3 feet) onto each of its six sides, then open it and inspect the contents. This simulates the forces a package typically experiences during shipping. Professional packaging labs use calibrated drop testers, but a manual test gives you a reasonable approximation.
Shipping Insurance: Protecting Your Investment
Even with perfect packing, accidents happen. Shipping insurance provides a financial safety net for when they do. Here's what you need to know:
- ●Carrier liability is limited. UPS and FedEx provide automatic coverage up to $100. USPS covers Priority Mail up to $50. Anything beyond that requires purchased insurance.
- ●Document your packing process. Take photos before, during, and after packing. Insurance claims are much easier to win with visual evidence of proper packaging.
- ●Third-party insurance is often cheaper. Companies like Shipsurance or InsureShip typically offer better rates than carrier-provided insurance, especially for high-value items.
- ●Insufficient packing voids claims. If a carrier determines that the item was inadequately packed, they can deny the claim regardless of insurance coverage. Proper packing isn't just about preventing damage — it's required for insurance to be valid.
Fragile Item Packing Checklist
Proper fragile item packing is both a science and an art. The good news is that it's a learnable skill, and once you have your process dialed in, your damage rate will drop dramatically. At Box Atlanta, we supply the boxes, cushioning materials, tape, and expert advice you need to protect your fragile shipments. Whether you need a handful of boxes for a move or pallets of packaging materials for your e-commerce operation, we're here to help.