How to Pack a Postal Box Properly for Maximum Protection
How to pack postal boxes correctly so products arrive undamaged every time.
Packing steps
Step-by-step packing0 / 6 checked
Quick answer
Choose the right size box, wrap the product, centre it with cushioning on all sides, fill all voids, and seal securely. The product should not move when the box is shaken. There should be at least 3-5cm of cushioning between the product and every box wall. Pack as if the box will be dropped from waist height, because during transit, it effectively will be.
Void fill options
The most eco-friendly option. Effective for preventing movement in most applications.
Excellent cushioning with a premium look. Fully recyclable and compostable.
Best for fragile items but not recyclable in kerbside recycling.
Good for filling large voids without adding weight. Less protective than wrapping materials.
Choose the right box: sizing guide or tape guide.
Packing fragile items
For fragile items, use the double-box method. Wrap the item, place it in a smaller box, then put that box inside a larger one with cushioning between. This creates an air gap that absorbs shocks. Ensure at least 5cm of cushioning between the inner and outer boxes on all sides.
Common mistakes
Postal boxes and packing supplies
Boxes, void fill, tape, and cushioning materials for professional postal packaging.
Browse postal boxesFrequently asked questions
At least 3-5cm between the product and every box wall. More for fragile items.
Crumpled kraft paper or honeycomb paper wrap. Both are recyclable and compostable.
Use the double-box method with 5cm+ of cushioning between the inner and outer boxes on all sides.
Never. Direct contact transfers impacts from the box to the product.
Shake the packed box. If nothing moves, it is well packed. Drop it from waist height as a final test.
Part of our guide
Product Guide: Postal Boxes
Expert guides on postal boxes, from sizing and materials to branding and cost optimisation.
Browse all guides →
