In ecommerce, reducing packaging waste without slowing down fulfilment is a constant challenge. In today’s sustainable world, customers are increasingly frustrated when they receive a box filled with more void fill than product as it feels wasteful and creates extra recycling for them to manage.

That’s where multi-height boxes, also known as variable-depth boxes, offer a practical solution. Designed to adapt to different product sizes, these boxes help businesses minimise void fill, reduce shipping costs, and improve packing efficiency.

When combined with crash lock boxes, they go even further, reducing the need for additional materials while speeding up fulfilment, improving pack security, and creating a positive brand impression with environmentally conscious customers.

Multi-height boxes (or variable-depth boxes) are boxes designed with pre-scored lines that allow packers to adjust the height of the box to suit the contents.

Instead of using multiple box sizes, one box can be resized on demand, reducing the need for excessive padding or void fill materials inside the parcel.

The Lil Crashlock combines the benefits of multi-height boxes with smart features designed for modern packing operations.

Each box includes variable-height perforations at every corner, allowing the height to be reduced quickly and cleanly without knives or cutting tools.

Benefits include:

• Fast, tool-free height adjustment
• Safer packing process for warehouse staff
• Consistent right-sizing of boxes for every order

Unlike standard boxes that rely on tape or a single adhesive strip, Lil Crashlock features twin peel & seal strips at the sides of the box.

Key advantages:

1. Faster fulfilment

• No tape required
• Quick, clean sealing
• Ideal for high-volume operations

2. Improved security

• Side seals create a stronger closure than a single strip across the top
• Reduces risk of accidental opening or tampering

Removing tape entirely also contributes to material reduction, supporting sustainable packaging goals.

Reduced Need for Void Fill

Traditional packing methods often rely heavily on extra materials like paper void fill, bubble wrap, and air pillows to protect products in transit. This usually happens because standard boxes don’t properly fit the product inside.

Multi-height Lil Crashlock boxes solve this problem by allowing the box height to be adjusted to fit the contents snugly. By reducing empty space, there’s far less need for additional packing materials.

The result is a more efficient packing process with clear benefits. You reduce reliance on extra components, create a neater and more compact parcel, and significantly cut costs. In fact, Lil Crashlock can save up to 40% in void fill, with variable height creases reducing box height by up to 60%.

Better Customer Experience

When customers open a parcel filled with excessive padding, it can leave the impression that the brand is wasteful and inefficient.

Using variable-depth Lil Crashlock boxes changes that experience completely. Customers receive only what’s necessary to protect their product.

This means less waste to deal with and a more thoughtful unboxing experience. It shows that your brand values both sustainability and customer convenience, helping to create a stronger, more positive impression.

Simpler, More Effective Recycling

Packaging that includes multiple materials can be frustrating and time-consuming to recycle.

By reducing or removing excess fillers, mixed materials, and unnecessary adhesives, multi-height crash lock boxes make recycling much simpler. The packaging is easier to separate, more likely to be fully recycled, and less likely to end up in landfill.

This simplicity benefits both businesses and end customers, making sustainable behaviour the easier choice.

Lower Impact Across the Supply Chain

Reducing materials doesn’t just improve the box itself. It has a ripple effect across the entire supply chain.

Packing becomes faster and more efficient, as there’s less need to handle additional materials. Parcels are more compact, improving transport efficiency and reducing wasted space in transit. And when the package reaches the customer, there’s less waste to dispose of.

All of this contributes to a more streamlined, cost-effective, and environmentally responsible packaging system.