Every ecommerce business feels the pressure of rising delivery charges. Courier fees, dimensional weight pricing, storage space, and even return rates all tie back to one factor that is often underestimated: packaging. The size, shape, weight and structure of a parcel can raise or lower delivery costs more than many operational teams realise. For mid-sized businesses competing on speed, price, and customer experience, packaging optimisation is a cost-saving strategy that directly impacts profitability.
This shift is being reinforced across the industry. According to the IMRG, UK courier costs and fulfilment pressures have continued to rise as parcel volumes grow, tightening margins for online retailers. As you might imagine, the businesses that manage packaging most effectively are the ones best positioned to keep delivery costs under control.
Most carriers now use dimensional weight pricing, which accounts for both weight and parcel volume. A package that’s larger than necessary can trigger higher charges even if it's relatively light. This affects everything from postal rates to third-party logistics storage costs. As such, excess packaging also increases the number of pallets required for outbound transport and the amount of space needed in fulfilment centres.
Poor product protection adds another layer of cost. If packaging fails to prevent damage in transit, your return rates rise. Returns are expensive, especially when they involve repacking, reprocessing, or product replacement. So for businesses working in high-volume categories like homeware, cosmetics, small appliances and electronics, the impact is significant.
Oversized cartons introduce friction across the entire workflow. As you might expect, larger parcels take more space on packing benches. They usually require more void fill to cushion products, and they slow down pack times because staff must compensate for unused space. They also create inefficiencies for couriers, who have limited van capacity and often reprice shipments to reflect this.
These costs add up quickly. Studies from packaging and fulfilment bodies such as the UKWA show that eliminating unnecessary void space can reduce volumetric costs and increase throughput capacity across storage and distribution.
When multiplied across thousands of monthly orders, even a small reduction in carton size or material use results in measurable savings.
Right-sizing is the process of matching packaging dimensions to the product being shipped with real precision. This reduces excess volume and ensures the correct level of protection. Common right-sizing strategies include switching to multiple carton formats instead of relying on one generic box size, redesigning packaging to remove unnecessary layers, and replacing bulky void fill with more waste-free, efficient cushioning.
Material optimisation also plays a major role. Heavier materials drive up courier costs, particularly when shipments are priced by weight. That’s why using strong, lightweight, fibre-based options is key, as it can lower both cost and environmental impact. And as you might imagine, they’re easier to handle on the packing line too.
We support these strategies with a wide range of packaging solutions designed for ecommerce. Our carton range includes crash-lock boxes, die-cut cartons, and book mailers designed to reduce space and improve packing speed. For cushioning, our sustainable paper void fill systems and FSC™ certified materials provide lightweight protection without increasing volumetric size and without relying on oil-based plastics. Find out more.
Packaging that's too small, too weak, or simply unsuitable for the product can (and usually will) cause damage during transit. Each damaged item equals a direct cost and a customer service problem. Stronger structural design, reinforced seals and impact-resistant cushioning all help maintain product integrity, particularly for fragile items.
The key is to balance protection with efficiency. That’s why it’s key to emphasise a well-chosen carton and the correct void fill, as they usually outperform oversized packaging that relies on excess cushioning. This approach improves customer satisfaction because orders arrive intact. It also improves sustainability because fewer materials are used and fewer products are wasted through damage.
As order volumes fluctuate, mid-sized businesses need packaging that can scale with demand. This means consistent availability, strong supply continuity, and the ability to adapt specifications when needed. It also means using packaging formats that reduce pack time and increase throughput, which becomes critical during seasonal peaks.
We support this need with rapid fulfilment from UK stock, multiple format options for different SKUs, and sustainable products that reduce dependency on global plastic markets. Our solutions help teams pack faster, reduce void space, cut material waste, and lower courier costs through more efficient parcel design. Combined with technical guidance, this lets businesses refine packaging specifications confidently and in line with operational goals.
Delivery costs are rising, and packaging is one of the most effective ways to manage them. Right-sizing, material optimisation, and better product protection offer practical, measurable savings across transport, storage, and returns. The result is consistent; businesses that treat packaging as a strategic lever rather than a background task gain a clear operational advantage.
We help businesses and operations of all sizes, from SMEs to national retailers, with reliable UK supply, scalable packaging systems, and a full range of sustainable materials that reduce both cost and environmental impact. If you would like to explore how to reduce delivery charges through packaging optimisation, we can help send us a message, email sales@allpack.uk.com, or call 01543 396 700