How to Pack Boxes (Part 2)


How to Pack Boxes (Part 2)


In Part 2 of 2 of our "How to Pack Boxes" guide, we cover Internal Packaging and Sealing the Box!

Step 3 - Internal Packaging


When we talk about internal packaging, we’re talking about all the packaging material that goes inside the box to ensure the contents are cushioned, protected and safe to be transported. There is quite a large range of internal packaging materials that can and should be used to wrap, cushion and protect the items safely inside the box.

Internal packaging is needed to ensure the items inside the box cannot move around and cause damage to one another. If there is room for things to move around inside the box then you’re going to get Some examples of internal packaging materials include Bubble wrap, foam wrap, foam pellets, crumpled paper, corrugated inserts.

Bubble wrap is the best and most versatile internal cushioning material. It provides cushioning, void fill, protection, and separation.

Packing a Single Box

Wrap fragile or breakable items with packing paper and bubble wrap. Don’t be afraid to use extra layers of bubble wrap. After all, better be safe than sorry!

Always place items in the centre of the box with at least 5cmof internal packaging as a cushion between the items and the walls and corners of the box.

If packing more than one item into a box, wrap each item individually with cushioning material. and use dividers such as corrugated inserts so items won’t hit each other and get damaged.

Ensure there is no empty space in the box, otherwise items will move around and potentially get damaged. Use cushioning, such as bubble wrap or crumpled packing paper, to fill all void spaces in the box – on the base, top, and sides. Under-filled boxes may collapse!

When choosing void filling cushioning, choose the appropriate density and thickness for the weight of the shipment contents. If you pack heavy or sharp items on the wrong type of internal packaging, they could s could sink, deflate under the weight or puncture bubble wrap or air pockets, and eventually result in empty space that provides little to no protection.

Store small items (e.g. nuts, screws, keys) in a ziplock bag or small container so that the items won’t separate during transit.

Ensure the box seals properly on top – never have anything sticking out of the top!

Double Box: Box-in-box method

Sometimes, boxes will have to be packed in another box. This method is often used for items such as:

  • Fragile items
  • Boxes used for retail purposes
  • Chipboard boxes like gift boxes or shoe boxes

In this instance, an outer box will be used to encase the original box.

The outer box should be at least 14cm longer, wider, and deeper than the inner box.

Place 5cm of void fill in the base of the outer box before placing the inner box in the centre. Place cushioning material on all sides before sealing the outer box.

Step 4 - Sealing your box


Tape the box well! Ensure the seams are securely sealed and reinforce areas where stress is concentrated. Use the H method of taping – apply tape across the flaps and seams to the top and bottom of the box. (illustrate)

Place delivery and contact information inside and outside the package

Place shipping labels on the box’s largest surface; avoid wrapping labels around the corner of the package. Labels should be applied facing the same direction on the same side.

Mark boxes appropriately with “FRAGILE”, “HEAVY”, and “THIS SIDE UP” to reduce the chance of mishandling.

Can’t fit your item into a box? PACK & SEND makes custom boxes for your awkwardly shaped item!

Think all of this is too much trouble? We’ll help you pack your items, no matter how big, awkward, or fragile they are!

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