How to Package a Parcel: Complete Packaging Guide
Poor packaging is the number one reason parcels arrive damaged. Get it right every time with this step-by-step guide.
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Why Packaging Matters
Couriers like DPD, Evri, and Royal Mail handle millions of parcels daily. Your package will be stacked, sorted by machines, loaded onto vans, and potentially dropped from waist height. If it is not packaged properly, the contents will not survive. Worse, couriers can refuse compensation claims if packaging is deemed inadequate.
Step 1: Choose the Right Box
Always use a corrugated cardboard box — not a shoebox. Double-walled boxes are best for items over 5kg. The box should be slightly larger than your item to allow room for cushioning material. Reusing boxes is fine as long as there are no tears, soft spots, or old labels. Remove or cover any previous barcodes.
- Under 2kg: Single-walled cardboard box or padded envelope
- 2-10kg: Single or double-walled box depending on fragility
- 10-30kg: Double-walled box, ideally with reinforced corners
- Over 30kg: Consider pallet shipping — see our pallet delivery guide
Step 2: Wrap and Cushion Your Item
Wrap the item itself in bubble wrap or tissue paper. Then fill the remaining space in the box with cushioning material. The golden rule: shake the box gently — if the contents move, add more filling.
- Bubble wrap — best for fragile items, wrap at least two layers
- Scrunched newspaper — free and effective for non-fragile items
- Packing peanuts — great for filling voids around oddly shaped items
- Air pillows — lightweight and professional, used by Amazon and other retailers
- Foam sheets — ideal for electronics and screens
Step 3: Seal It Properly
Use brown parcel tape or reinforced packing tape. Apply tape along all seams — top, bottom, and the opening. The H-taping method (tape across the opening, then along both edges) is the most secure. Never use masking tape, sellotape, or string — they will not hold during transit.
Step 4: Label Correctly
Place the shipping label on the largest flat surface of the box. Do not place it on a seam or over tape joins. If using a printed label, cover it with clear tape to protect from rain. Include a return address inside the box in case the external label is lost.
Courier-Specific Packaging Rules
| Courier | Max Weight | Max Length | Notes |
|---|---|---|---|
| Royal Mail | 30kg | 2.5m combined L+W+H | No parcel tape on padded envelopes for letterbox items |
| Evri | 15kg | 120cm longest side | Must fit through ParcelShop door |
| DPD | 30kg | 175cm longest side | Accepts most standard boxes |
| UPS | 70kg | 274cm longest side | Over 32kg requires heavy label |
| FedEx | 68kg | 274cm longest side | Custom packaging available for business accounts |
| DHL | 70kg | 300cm L+2(W+H) | Express Worldwide accepts larger items |
Where to Get Packaging Materials
You do not need to spend a fortune. Supermarkets give away boxes for free — ask at the back of Tesco or Sainsbury's. Bubble wrap and tape are cheapest from Poundland or Amazon in bulk. For professional packaging, courier branded boxes from DPD and Royal Mail are available at their collection points.
Common Mistakes to Avoid
- Using a box that is too large with insufficient filling
- Wrapping items in carrier bags instead of proper cushioning
- Sealing with sellotape that peels off in transit
- Not removing old barcodes from reused boxes
- Placing the label on a curved or taped surface
Compare Courier Prices
Once your parcel is packaged, weigh it and measure its dimensions. Then use our price comparison tool to find the cheapest courier. Prices vary dramatically — a 5kg parcel can cost anywhere from £3.49 with Evri to £15+ with Royal Mail over the counter.