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Low cost self seal postal packaging – prices checked weekly

Become an Expert in Fulfilment Packaging

(imrg.org UK consumer home delivery survey)

1. Have you received an item that was damaged? 46% yes / 54% no

2. Why: 45.08%
Insufficient/ inappropriate packaging, 31.80% Poor handling by delivery personnel, 9.85% Item fault during manufacturing, 7.65% Other, 5.62% item being left in an insecure place

3. Have you received an item with inappropriate packaging? 43% yes/ 57% no

4. Was the packaging: 71.03%
too little, 10.56% too big to fit in my letterbox/mailbox, 9.91% too big for the item it contained, 6.32% too much, 2.18% other

5. Has bad packaging prevented you from ordering again from the same
company? 78% yes / 10% no (12% maybe)

1- Fit Large Letter

It’s not just about the size (353x250x25mm), it cant be floppy! Fashion retailers need to think outside the £0.10 polythene mailbag to save £1 posting shirts. Opt for sturdy letterbox packaging. Corrugated envelopes or book wraps are often the best option.

See the Royal Mail Size Guide.

Royal Mail Item Size Guide
E-Commerce Packaging from Lil Packaging

iMRG chief Editor statement

“ Value= Sales – Buying Costs – Operational costs – Marketing”

Beautiful packaging WILL: S: Increase loyalty from the 35% norm (25% fashion). B: no void fill. No sealing tape. O: 2x faster & achieve better than 25% ecom returns. M: Beautiful unboxing experiences = social dream.

2- Letterbox Packaging

UK standard letterboxes are either 10” or 12” wide. They are commonly 1.5” high.

Minimising ‘failed to deliver’ returns with letterbox packaging = more happy consumers. Many are catching on to the benefits of letterbox sized gifts. 

Letterbox Packaging
Letterbox Size Packaging
Hot Melt Glue | Lil Packaging

3. Hot melt, hot melt, hot melt!

Peel & Seal Boxes and self seal boxes rather than basic cardboard boxes are undoubtedly the future of ecommerce Packaging. Enter hot melt glue:

• Fastest method of fulfilment

• No need for tape = £ saved, space made & best unboxing experience

• Coupled with red tear-strip means frustration-free opening

• Why hot melt ?

• 6min curing time • fast release overhanging paper • 300% more aggressive bond than double-sided tape.

The only other type of peel & seal is inferior pre-produced double-sided tape. Some cheap manufacturers do this in-line while converting bags/mailers or on the corrugators before making boxes. Only trust hot melt.

4. Rank competitors packaging

Perform competitor test orders to understand what you’re up against for delivery experience.

Rank your packaging chart

The trick is to be perceived as high-end without paying high-end… and by fulfilling faster than your competition.

5. Speed, speed, speeeeeeeed!

Doubling fulfilment speed = half manpower required

(the savings are as simple as that)

Examples : 

1. Die cut blank Shirt box vs Mailbox

2. 0201*vs crash lock
*google FEFCO style 0201 (it’s too boring to discuss). They're the first style you think of in a classic "cardboard box".

FEFCO = European Federation of Corrugated Board Manufacturers

Fulfil orders quickly

6. Crashlock Crashlock Crashlock!

Crash lock boxes are undoubtedly the fastest box to pack in the marketplace.

Department Store attendee asked us 2016: “My Director has instructed me to source crash lock boxes to handle our 250% growth.”

Reinforced Crashlock Base Box
Reinforced Crashlock Base Carton

7. Avoid voidfill like the plague!

Voidfill is widely regarded as the biggest waste of money in the packaging industry and it’s true.

Sadly there are only 3 methods of avoiding it:

1. Variable-depth packaging (twistwraps)

2. Retention packaging (integrated cohesive tissue)

3. Custom-made snug fit boxes. Why not go for bespoke printed postal boxes?

L-EG-01 Twistwrap | Lil Packaging
UK Cardboard Manufacturing

Unlike overseas manufacturers, most UK cardboard boxes producer’s MOQ is only 1 full pallet of each SKU. All UK packaging distributors are targeted to achieve 40% gross profit. This means 66.67% mark-up. While they’re prepared to do 10% GP on some lines, they’ll need to compensate with 70% GP on other lines. Avoid paying for the middle-man on any shipping boxes SKU over 1 pallet.

8. Buy direct from UK manufacturers!

9. BCT to avoid a soggy-bottom box!

95% of corrugated is across 2 profiles : 80% B flute and 15% E flute.

Specifying a BCT value (box compression test) for your boxes is the only way of ensuring your supplier is not compromising your quality standards over time.

Don’t go lower than 1,500 BCT for ecom up to 1.5kg average (gram = BCT rule) for your shipping boxes.

  • Box Compression Test Graph

    Kraft (Virgin-fibre) is 30% more expensive but since 2010 Test
    additives nearly match the strength of kraft.

  • 10. Take advantage of in-line processes (eg. in-line printing).

    • Always ask your supplier to explain the processes of manufacturing each of your shipping boxes.

    • Identify what upgrades can be made with in-line processes to avoid significant extra cost.

    • Identify whether amending specifications slightly mean lines can be produced more efficiently.

  • Lil Packaging Unboxing Experience
  • Packaging economies of scale

  • 11. Economies of scale

    Every time your volumes increase in excess of 50% it is likely that your supplier will be able to offer improved pricing.

    Don’t ask, don’t get.

12. Final touchpoint is unboxing experience

We cant expect consumers loyalty without a positive final experience which is often lacking in plain cardboard boxes.

Don’t let them down   ask your packaging supplier for ideas for custom printed postal boxes.

Custom Bespoke Packaging | Space NK
bespoke.jpeg__PID:17d457b4-a5d5-4b18-b878-d04a4b624f46