Costly Packaging Mistakes Small Businesses Should Avoid

Author | Updated Date: 11/21/2025

Introduction – Why Packaging Mistakes Are More Expensive Than You Think

For small businesses, packaging is often an afterthought. But here’s the truth: poor packaging decisions cost far more than you realise. From product damage and higher returns to expensive shipping and branding failures, the wrong packaging can quietly chip away at your profits and customer trust.

In this post, we’ll unpack the most common packaging mistakes small businesses make—and how to avoid them.

Mistake #1: Choosing the Wrong Packaging Size

Biggest cost? Shipping.

Oversized boxes not only inflate your courier costs—they require more void fill, take up warehouse space, and frustrate eco-conscious customers. Undersized packaging, on the other hand, leads to crushed products and disappointed buyers.

✅ Packaging Tip: Always match box dimensions to your product. Custom-sized boxes reduce filler, lower shipping weight, and prevent damage.

Mistake #2: Using Low-Quality Packaging Materials

Cheap materials might save pennies upfront, but the long-term costs include damaged goods, poor reviews, and repeat returns.

Weak cardboard collapses under pressure
Flimsy mailers tear in transit
Poor adhesives lead to open boxes

Your product deserves to arrive safely and beautifully.

✅ Packaging Tip: Invest in durable corrugated or kraft board. Choose materials suited for your product’s weight and fragility.

Mistake #3: Ignoring Brand Identity in Packaging

Plain packaging might work for shipping—but it won’t build a brand.

In the age of social media unboxing and customer experience, generic boxes are a missed opportunity. Even small businesses benefit from consistent logos, colour schemes, and messaging.

✅ Packaging Tip: Use custom printed boxes to increase brand recall, create excitement, and tell your brand story from the outside in.

Mistake #4: Overcomplicating the Packaging Design

Too much text, confusing artwork, or hard-to-open structures frustrate customers. Packaging should be simple, functional, and attractive.

✅ Packaging Tip: Stick to a clean, minimal layout with intuitive opening. Use icons and typography that are easy to scan.

Mistake #5: Not Considering Packaging Protection Needs

If your product is fragile, oily, liquid, or premium—your packaging must match.

Fragile items need foam inserts or corrugated walls
Liquids require leak-proof liners
Glass jars need snug internal cavities

✅ Packaging Tip: Always assess drop resistance, moisture protection, and material compatibility.

Mistake #6: Overlooking Eco-Friendly Options

Today’s consumers care deeply about sustainability. Packaging that ends up in landfill damages your reputation and the planet.

✅ Packaging Tip: Use recyclable cardboard, soy-based inks, and minimal plastic. Kraft packaging is a small business favourite for eco-conscious branding.

Mistake #7: Not Planning Packaging for Shipping

Retail packaging isn’t always strong enough for courier handling. If your packaging isn’t tested for stacking, vibration, and drops—it may not survive.

✅ Packaging Tip: Run real-world stress tests or ask your supplier about eCommerce-ready box styles like crash-lock bottoms or double-wall corrugated.

Mistake #8: Misprinting or Missing Important Information

Especially for cosmetics, food, supplements, or regulated products—missing information is a legal risk.

No barcode? Can’t sell retail.
Wrong label size? Confuses buyers.
Missing ingredients or warnings? Dangerous.

✅ Packaging Tip: Triple-check your label compliance, and always proof before printing.

Mistake #9: Failing to Order Packaging in Advance

Last-minute orders mean rushed design, higher costs, and the risk of running out during peak season.

✅ Packaging Tip: Order 4–6 weeks before your busy period. Bulk orders lower your per-unit price.

Mistake #10: Not Working With the Right Packaging Supplier

All suppliers are not created equal. The cheapest isn’t always the best—especially when it comes to customisation, material quality, or delivery reliability.

✅ Packaging Tip: Work with an experienced partner like BuyPackagingBoxes.co.uk. We specialise in helping small businesses scale with high-quality custom packaging at affordable rates.

Actionable Tips to Improve Your Packaging Strategy Today

Here’s how you can start improving today:

Conduct a packaging audit for waste or damage trends
Use custom-sized boxes to save space and reduce filler
Upgrade materials to corrugated, rigid, or kraft board
Switch to printed packaging for better brand presence
Ask your supplier for free mockups or dieline support

Conclusion

Every small business makes packaging mistakes—it’s how you learn. But when you avoid the most common pitfalls, you save money, protect your products, and elevate your brand.

The right packaging isn’t just a box—it’s your brand’s first impression. Make it count.

Stop Packaging Mistakes Before They Start

Get custom packaging that’s smart, safe, and built for your business. From design to delivery, we’ve got your back.

Request a Free Quote

Quick Answers on Packaging for Small Business Owners

What is the most common packaging mistake small businesses make?

Using the wrong box size—either too big or too small—leads to shipping issues and product damage.

Why is custom-sized packaging important?

It reduces filler, prevents damage, and lowers shipping costs.

How does packaging affect shipping costs?

Larger or heavier boxes cost more to ship. Couriers charge based on size and weight.

Can eco-friendly packaging save small businesses money?

Yes! Kraft and recyclable materials often cost less in bulk and align with customer values.

How do I choose the right packaging supplier?

Look for reliability, material quality, customisation options, and design support—like BuyPackagingBoxes.co.uk offers.