Why and How to Use Discreet Packaging for Shipping
In this article
8 minutes
- What is Discreet Shipping?
- Why Discreet Packaging Matters for Customer Privacy
- Sensitive Items That Require Discreet Packaging
- Types of Discreet Packaging Materials
- How to Pack Discreetly: Step-by-Step Guide
- Customizing Your Shipping Label
- Choosing the Right Carrier for Discreet Shipping
- International Discreet Shipping Considerations
- Additional Tips for Discreet Packaging and Shipping
- Benefits of Discreet Packaging and Shipping
- Summary
- Frequently Asked Questions
In today’s world, consumers place a premium on privacy. For many, the need for discreet packaging stems from a desire to maintain confidentiality about the products they purchase. Discreet packaging for shipping can help businesses cater to this need, fostering customer trust and loyalty. This guide covers which items benefit from discreet packaging, the types of discreet packaging available, and best practices for packing items securely and privately.
What is Discreet Shipping?
Discreet shipping is a method designed to ensure that the contents of a package remain confidential and unidentifiable. This approach is particularly important for sensitive, valuable, or confidential items such as medical devices, luxury items, or adult products. By using plain packaging materials like unmarked brown or white boxes, businesses can effectively conceal the contents of the package. This not only helps in maintaining customer anonymity but also builds customer trust and satisfaction. Discreet shipping is a key strategy for businesses aiming to respect their customers’ privacy and enhance their overall shopping experience.
Why Discreet Packaging Matters for Customer Privacy
Fifty-eight percent (58%) of consumers are concerned about the amount of personal information visible on product packaging, especially concerning returns and delivery details, according to a 2021 study by the Institute of Packaging Professionals (IoPP). This increasing demand for secure, private packaging that prevents the unintended exposure of personal or sensitive information during shipping and handling highlights the importance of thoughtful design in ecommerce packaging.
Requiring an adult signature for sensitive deliveries can further enhance discretion and security, ensuring that packages are handed directly to an adult at the recipient’s home.
Discreet packaging serves several purposes:
- Privacy: Protects the buyer’s confidentiality by concealing the contents of the package.
- Security: Reduces theft risk by not advertising valuable or sensitive items.
- Customer Experience: Enhances satisfaction by addressing concerns about privacy and security.
By offering discreet packaging, businesses can differentiate themselves and build stronger customer relationships.
Sensitive Items That Require Discreet Packaging
While any product can be shipped discreetly, certain categories typically necessitate it:
- Personal Care and Health Products:
- Examples: Birth control, medications, hygiene products, and wellness items.
- Reason: Customers value privacy for sensitive or potentially embarrassing items.
- Adult Products:
- Examples: Intimacy aids, lingerie, and other adult-related goods.
- Reason: Customers expect confidentiality to avoid awkward situations with family members or neighbors.
- High-Value Items:
- Examples: Electronics, jewelry, and luxury goods.
- Reason: High-value items are more prone to theft and porch piracy.
- Specialty Products:
- Examples: Medical devices, religious items, or niche-interest goods.
- Reason: Customers may wish to avoid judgment or maintain personal privacy.
- Subscription Boxes:
- Examples: Personal hygiene kits, curated collections, or food delivery.
- Reason: Neutral packaging ensures privacy while protecting brand reputation.
Types of Discreet Packaging Materials
The choice of discreet packaging depends on the product, shipping method, and budget. Here are some common options:
- Plain Boxes:
- Features: Unmarked, logo-free, neutral colors (brown or white).
- Best For: Bulkier items, electronics, and subscription boxes.
- Tips: Ensure the box size closely matches the product to avoid shifting during transit.
- Opaque Poly Mailers:
- Features: Lightweight, durable, and non-transparent.
- Best For: Soft goods like clothing or small items.
- Tips: Use bubble-lined mailers to protect more fragile items.
- Blackout or Double-Layered Packaging:
- Features: Enhanced opacity for ultimate privacy.
- Best For: High-sensitivity items such as adult products or medical devices.
- Tips: Seal securely to prevent tampering.
- Tamper-Evident Packaging:
- Features: Seals that indicate if the package has been opened.
- Best For: High-value goods and confidential documents.
- Tips: Include clear instructions for opening without damaging the product.
- Custom Packaging:
- Features: Unique designs that are discreet but still align with branding.
- Best For: Businesses wanting to combine privacy with subtle marketing.
- Tips: Avoid overt branding that could hint at the contents.
How to Pack Discreetly: Step-by-Step Guide
Ensuring items are both secure and private requires attention to detail. Here are the steps:
- Select the Right Packaging Material:
- Choose a box or mailer that fits the product snugly to minimize movement during shipping.
- Use opaque materials to prevent the visibility of package contents.
- Wrap the Product:
- Use protective materials like bubble wrap, tissue paper, or packing peanuts to cushion the item.
- Wrap sensitive products in a layer of plain paper or a blackout bag.
- Seal the Package Securely:
- Use strong adhesive tape to seal all openings.
- Consider tamper-evident seals for added security.
- Label Discreetly:
- Avoid using company logos or names that hint at the contents.
- Use a generic sender name and return address.
- Test the Package:
- Shake the package gently to ensure there is no movement inside.
- Inspect the outer layer for any gaps or weak spots.
Customizing Your Shipping Label
Customizing your shipping label is a crucial step in maintaining discretion during shipping. A shipping label can inadvertently reveal a lot about the package, including the sender’s and recipient’s details, as well as the package’s weight and dimensions. To ensure discretion, ecommerce businesses should consider using plain labels that only include the necessary information, such as the recipient’s name and address. Additionally, using a generic sender name and a return address that is not directly associated with the company can further enhance privacy. This careful customization of shipping labels helps in preserving the discreet nature of the package, ensuring that customers feel secure and confident in their purchases.
Choosing the Right Carrier for Discreet Shipping
Selecting the right carrier is essential for effective discreet shipping. Different carriers have varying shipping requirements and policies, and some may be better suited for maintaining discretion than others. For instance, certain carriers might require delivery signatures, which could compromise the discreet nature of the package. Others may have specific packaging and labeling requirements that could impact privacy. Ecommerce businesses should thoroughly research and compare carriers to find one that aligns with their discreet shipping needs. By choosing a carrier that supports discreet shipping practices, businesses can ensure that their customers’ privacy is upheld throughout the delivery process.
International Discreet Shipping Considerations
When it comes to international discreet shipping, additional considerations come into play. Ecommerce businesses must navigate customs and import regulations, which can sometimes affect the discretion of the package. For example, some countries may mandate specific labeling or packaging for certain products, potentially compromising privacy. Moreover, international shipping often involves multiple carriers and handlers, increasing the risk of packages being opened or inspected. To mitigate these risks, businesses should research and comply with international shipping regulations and consider partnering with carriers that specialize in discreet international shipping. This ensures that even when shipping across borders, customer privacy and confidentiality are maintained.
Additional Tips for Discreet Packaging and Shipping
- Communicate with Customers:
- Clearly offer discreet packaging and shipping options on your website or during the checkout process.
- Provide tracking numbers so customers know when to expect delivery.
- Eco-Friendly Options:
- Opt for recyclable or biodegradable materials to appeal to environmentally conscious customers.
- Use water-based adhesives and compostable materials.
- Double-Boxing for Extra Privacy:
- Place the product in a branded inner box and an unmarked outer box.
- This ensures branding is maintained while providing full discretion.
- Avoid Over-Packaging:
- Minimize waste by using the smallest possible box or mailer that fits the item securely.
- Too much (or too large) packaging can be off-putting for eco-conscious customers.
- Excess packaging will increase the dimensional (DIM) weight, leading to higher shipping costs.
- Train Your Staff:
- Educate your packing team on the importance of privacy and proper techniques for discreet packaging.
Benefits of Discreet Packaging and Shipping
Discreet packaging and shipping offer several key benefits for businesses looking to enhance customer experience and stand out in the market. One of the most significant advantages is enhanced customer loyalty. By respecting customer privacy, businesses build trust, which encourages repeat purchases and long-term relationships with their audience. When customers feel secure in their transactions, they are more likely to return.
Another advantage is a reduction in returns and complaints. Discreet packaging helps minimize potential embarrassment or dissatisfaction that may arise from receiving an easily identifiable package. This, in turn, leads to fewer ecommerce returns, saving businesses time and resources while improving overall customer satisfaction.
Additionally, improved security is a crucial benefit of discreet shipping. Unmarked packages are less likely to attract attention during transit or after delivery, reducing the risk of theft. This is particularly important for high-value or sensitive products that could otherwise be targeted.
Finally, discreet packaging can serve as a powerful differentiator in competitive industries. In markets where many businesses offer similar products, taking extra steps to ensure customer privacy can set a brand apart, strengthening its reputation and attracting a loyal customer base. By prioritizing discreet shipping, businesses not only enhance security and satisfaction but also gain a competitive edge.
Summary
Discreet packaging is more than a logistical choice; it’s a customer-centric strategy that addresses privacy, security, and satisfaction. By understanding the needs of your audience and implementing the right packaging techniques, you can enhance your brand’s reputation and build lasting relationships with your customers. Whether shipping personal care items or high-value electronics, this guide equips you to deliver with discretion and professionalism. Cahoot’s innovative fulfillment solution provides many such services that set you apart from other Sellers in your industry.
Frequently Asked Questions
What is Discreet Packaging?
Discreet packaging obscures the contents of the shipment, allowing sensitive items to be shipped incognito.
Why Use Discreet Packaging?
Discreet packaging helps protect customer information and the nature of their ordered items, preventing sensitive or high-value items from being noticed during shipping.
Is Discreet Packaging Legal?
Yes, as long as the package meets required postage and shipping regulations, such as a proper label with the recipient’s address.

Up to 64% Lower Returns Processing Cost

PONY UP Act: USPS Could Be Paying for Late Deliveries
In this article
3 minutes
Mail delivery has become increasingly unreliable, and lawmakers are taking action. Legislators have reintroduced the PONY UP Act, a bold legislative effort to address chronic delays in postal service by holding the United States Postal Service financially responsible for late deliveries. The proposal has sparked discussions across industries, particularly within the e-commerce sector, which relies heavily on timely delivery to meet customer expectations. If passed, the legislation could introduce new financial liabilities for USPS while reshaping the landscape for online sellers and consumers alike.
Understanding the PONY UP Act
Formally known as the “Penalizing Oversight Neglecting Your Universal Postal Service” (PONY UP) Act, this bill seeks to reimburse consumers for late fees incurred due to delayed USPS deliveries. Specifically, it would require USPS to cover penalties arising from tardy bill payments (e.g., that pesky $35 late fee when a credit card payment is not received on time) when the delay results from late mail service. The legislation is in response to many complaints about unreliable delivery service that has led to financial burdens for its users.
The regulation would apply to situations where a bill, notice, or payment was mailed with ample time to arrive before its due date but was delivered late. It also proposes an online and in-person claims process for reimbursement and an appeal mechanism for denied claims. Additionally, the legislation mandates annual reports on USPS delivery performance to improve transparency and oversight.
Why the PONY UP Act is Being Introduced
USPS has faced increasing scrutiny over delivery inefficiencies, particularly in rural areas, which have frequent delays. Audits have revealed significant lags in sorting and delivering mail. Reports cite instances of late medical payments, utility bills, and even time-sensitive shipments such as live poultry for agricultural businesses. These delays have led to growing frustration among consumers and businesses that depend on consistent delivery expectations for financial stability and operational continuity.
Legislators argue that the PONY UP Act will create a stronger incentive for USPS to prioritize service reliability. By attaching financial consequences to delivery failures, the bill aims to ensure that USPS meets its congressionally mandated six-day delivery obligation while providing relief to those negatively affected by missed service level agreements (SLAs).
Potential Impacts on E-Commerce
If the PONY UP Act becomes law, it could mean several things for the e-commerce industry, which relies heavily on USPS for daily business operations:
- Improved Delivery Performance: The prospect of financial penalties may push USPS to improve efficiency. Fewer delays translate to increased consumer confidence in delivery expectations for online purchases.
- Rising Shipping Costs: USPS may need to increase shipping rates to offset potential investments required to meet the expectations established by law. Those fees would be passed onto e-commerce businesses, pushing operational costs higher and creating margin pressure for merchants of small, light, and inexpensive items that are heavily reliant on USPS for affordable shipping solutions to turn a profit. They may be unduly forced to adjust product and pricing strategies and/or explore alternative carriers to remain viable.
- Greater Emphasis on Delivery Guarantees: Online retailers that depend on USPS’s Priority Mail and other expedited services may benefit from increased accountability, as USPS would be compelled to meet delivery SLAs. Late deliveries are rarely the result of late shipping. E-commerce businesses, as a whole, are very good at meeting their customers’ on-time shipping obligations. As the carrier’s delivery reliability increases, so does consumer trust, resulting in more online shopping and, thus, more growth and prosperity for the industry.
- Changes in Carrier Strategies: One e-commerce Seller told me, “Almost anything is better than USPS; I’m confident that a messenger pigeon is better than USPS.” As confidence in USPS increases, more merchants who had lost faith in the service and migrated to more reliable national carriers may reintroduce lower-cost USPS services to improve their profit margins.
Shipping and logistics are pivotal to the success of online retail, and any regulatory changes affecting USPS operations will inevitably profoundly impact the industry. Retailers and brands should monitor legislative developments and be prepared to adapt to potential cost increases or modifications to service levels.
Summary
The PONY UP Act is an effort to address longstanding issues with USPS delivery delays. It provides a mechanism for consumer protection while aiming to drive operational improvements. While primarily intended to target and remedy first-class mail service issues, its potential impact on e-commerce remains speculative. While increased accountability could enhance service reliability, shipping rate hikes could challenge Sellers dependent on affordable delivery options.

Up to 64% Lower Returns Processing Cost

2025 NMFC Changes for LTL Freight Shipments (Improved Classification)
The National Motor Freight Classification (NMFC) system was established in 1936 to standardize Less-Than-Truckload (LTL) shipping. It uses a uniform system for classifying commodities to ensure consistency and fairness in pricing and handling. The NMFC system is undergoing a significant transformation for the first time in decades. Starting July 19, 2025, the industry will begin a multi-phased shift to a predominantly density-based classification system to achieve greater clarity and efficiency for all stakeholders in the LTL supply chain.
Traditionally, the NMFC has evaluated freight based on 4 characteristics: density, stowability, handling, and liability. While comprehensive, this complex system leads to frequent misinterpretations and disputes between shippers and carriers (which can drag out for years). The 2025 update intends to streamline this process by using density as the primary means for classifying the vast majority of freight shipments, while the remaining 3 characteristics will be reserved for classifying only the more complicated commodities. Let’s look at each in more detail:
- Density refers to how much a shipment weighs compared to the space it occupies. Higher density typically results in a lower freight class and lower shipping costs because these shipments take up less space on a truck. For example, a small box of steel parts weighing 200 pounds in a small cubic space is denser than a large box of pillows weighing 200 pounds.
- Handling considers how easy or difficult it is to move freight. Heavy, fragile, oddly shaped, or hazardous items often require special handling, increasing the freight class and, thus, the cost. For example, a granite countertop may need extra care due to its weight and fragility, while a box of sand is easier to manage despite being dense.
- Stowability refers to how well the shipment fits in the carrier’s space (e.g., a 53-foot trailer). Again, size, shape, or transportation restrictions on certain items (e.g., hazardous materials) can make freight more challenging to load on a truck (think about a poorly played game of Tetris), leading to higher costs. For example, a shipment of pipes with irregular protrusions may leave unusable gaps in the truck. In contrast, neatly packed boxes fit more efficiently, allowing for the truck to move more items in a given move from point A to point B.
- Liability measures the risk associated with the goods, including susceptibility to damage, potential to harm other goods, perishability, and/or hazardous considerations. For example, a shipment of fresh produce is perishable and requires more careful handling and faster transit than a carton of vitamins, which is durable and lower risk.
Key Changes Coming in 2025
The new NMFC structure introduces several significant changes, notably the expansion of the density scale. Moving from 11 subprovisions to 13, the system now includes classes 50 and 55 for heavy, dense products. Approximately 5,000 commodity listings will be affected, with an estimated 3,500 single-class items moving to the new subcategories.
The updated classification system maintains all 4 of the transportation characteristics. Still, as noted above, it aims to simplify the classification process by defaulting to density-based classification when NO special handling, stowability, or liability concerns are known. In addition, products requiring special consideration will be marked with a new unique identifier, making it easier to identify freight that needs additional attention.
The transition begins with the public release of Docket 2025-1 on January 30, 2025, and the final implementation becomes effective on Saturday, July 19, 2025. Docket 2025-1 is the list of NMFC codes considered for class changes based on the new density scale (nearly 40%). Once the list is finalized, changes will be made before the effective date.
Impact on Shippers and Third-Party Logistics (3PL) Companies
The simplified system should make identifying the correct freight classes for most shipments easier but still rely on accurately measuring and reporting “handling unit” dimensions and weight (pallet length, width, height, and weight) used to calculate density. In short, Shippers and 3PLs can multiply length x width x height in inches, divide by 1,728 to convert cubic inches to cubic feet, and then divide the shipment weight by the cubic feet to determine pounds per cubic foot (PCF). Don’t forget to include the ~6-inch height and ~30-pound weight of the pallets. Carriers will still remeasure/reweigh and reclass/rebill for underreported shipment details.
Preparing for the Transition
To prepare for these changes, organizations should:
- Train Personnel: Educate staff on density calculations and measurement techniques. Providing training in advance will help reduce errors.
- Start Now: Begin creating shipments with accurate dimensions and weights now (if it’s not already being done), so it becomes second nature and prevents tendering delays later.
- Assess Current Shipping Pricing: Evaluate historical shipment pricing and contact carriers to identify areas where the updated density-based classifications might affect pricing.
- Implement Reliable Processes: Establish workflows to ensure every shipment is measured, weighed, and documented correctly before leaving the dock. Documenting shipments early could help resolve disputes more quickly.
Summary
While the initial transition may present challenges, the long-term benefits of modernizing the NMFC system may be considerable. The simplified, standardized approach should reduce classification errors (and thus, disputes), improve and quicken communication between parties, and create a more efficient LTL shipping workflow. Future dockets beyond 2025-1 will continue to refine the system, particularly for freight with specific handling, stowability, or liability requirements. Guidance on the timing of future dockets (NMFC improvements) has not been announced.

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Cartonization Software: A Must for Retailers and 3PLs in 2025
As e-commerce continues to grow and margin pressure peaks in today’s inflationary environment (e.g., labor cost, postage cost, etc.), online businesses must find ways to mitigate the mounting financial challenges by optimizing processes and workflows to reduce the overall cost of operations. Among the lowest-hanging fruit, one such method is to implement intelligent cartonization software to improve shipment efficiency and address the cost of postage, packaging, and labor while promoting sustainability. This technology utilizes sophisticated algorithms to identify the most efficient packaging to ship an e-commerce order by “fitting” products with known outer dimensions into a virtual 3D space with known inner dimensions. All while considering the shipping cost (actual weight vs. dimensional weight).
Understanding Cartonization Software
Cartonization software is a data-driven solution that determines the ideal packaging configuration for any given order, whether a single item or a multi-line/multi-quantity order. Unlike manual packing methods that rely on a human to eyeball the items in an order and select a box to ship them in, this technology analyzes many variables, from item dimensions and weights to available box sizes, any defined special handling requirements such as bubble wrap or other protective shipping supply requirements, among other packing constraints. Modern cartonization technology and packing systems incorporate 3D simulation and consider real-world factors such as orientation, stacking limitations, and the potential for damage in transit.
What sets intelligent cartonization software apart is its holistic approach. It does not merely calculate volume or dimensions; it optimizes the packing process to ensure items are securely packed using the least space. By doing so, the software minimizes unnecessary filler materials (while maintaining necessary cushioning as needed) and, ultimately, package size, directly impacting transportation and shipping supplies costs. Heavier and bulkier packages are more expensive to ship, and larger and more rigid cardboard boxes are more costly to consume.
Types of Cartonization Technologies
- Basic Cartonization Tools: These entry-level systems focus on volume-based calculations. They streamline box selection but lack advanced features such as considering shipping rates, displaying 3D orientation, or tracking the packaging quantity available.
- Advanced Algorithmic Solutions: These systems go beyond basic calculations by analyzing complex datasets. They consider multiple carrier rates, including dimensional weight pricing, and order-specific nuances, such as the need for temperature control or fragile item handling.
- Intelligent Fulfillment Platforms: These robust solutions combine cartonization with other aspects of order and inventory management software, such as tracking product and packaging inventory (what good is a cartonization tool if it tells you to pack an order in a box you don’t have in stock), multi-carrier shipping logistics, including carrier and service selection, and automatic label creation based on the delivery date promise. They provide end-to-end visibility into the fulfillment workflow.
Impact on E-commerce Fulfillment
Cartonization software has a profound influence on the efficiency and sustainability of e-commerce fulfillment operations:
- Operational Efficiency
Implementing cartonization technology significantly streamlines warehouse operations. By providing precise instructions for box selection and item placement (the orientation that each item should be placed in the box relative to one another such that they fit snugly and ship safely), the technology reduces decision fatigue among packers and improves consistency. Manually picking a box that is too small results in re-handling: a new box needs to be selected that will fit the contents of the order, which is re-work. Manually picking a box that’s too big means you’re shipping a lot of “air” and both the shipping cost and packaging cost are higher than they need to be, spoiling margins unnecessarily and increasing the likelihood that items may be damaged in transit (the resulting customer returns further add to the financial implications).
Advanced platforms can also create a separate pick list for the packaging supplies needed to ship a batch of orders. These features save a lot of time and increase productivity, enabling warehouse operations teams to seamlessly handle surges in fulfillment volume without increasing labor costs. - Cost Optimization
The financial benefits of smart cartonization extend across the entire fulfillment workflow. In addition to minimizing shipping costs by shipping in the smallest package possible, right-sizing packages reduce the need for void fill and the risk of product returns due to damage incurred in transit. Some platforms can identify opportunities to split orders into multiple packages, leveraging carrier incentives to achieve overall cost savings. - Environmental Sustainability
Cartonization software also promotes sustainability. By minimizing the use of corrugated materials and reducing the volume of “air” shipped in oversized boxes, the technology directly decreases the environmental footprint of e-commerce operations. Smaller, more efficient packages lead to better truck space utilization, resulting in fewer vehicles on the road, fewer planes in the air, and reduced greenhouse gas emissions. This aligns with growing consumer expectations for environmentally responsible ecommerce logistics practices. - Customer Experience
Consumers appreciate receiving their orders in appropriately sized packaging. Oversized or poorly packed boxes create unnecessary waste, diminishing the overall unboxing and post-purchase experience. They are also head-scratchers for customers (not to mention more annoying when breaking down larger boxes than smaller ones). Nearly 25% of solid municipal waste is composed of paper and corrugated paper products (cardboard), so shipping supplies are being sent to landfills at staggering rates, posing significant ecological consequences.
Cartonization software ensures customers receive their purchases in well-fitted, secure packaging, enhancing satisfaction and fostering brand loyalty. Moreover, using environmentally conscious packing methods resonates positively with eco-conscious customers, adding another layer of value.
Challenges and Considerations
While cartonization software offers numerous benefits, its implementation is not without challenges. Both retailers and 3PLs (third-party logistics) must invest in the right technology and ensure seamless integration with existing warehouse management and order fulfillment systems—otherwise, productivity tanks from having to live in separate fulfillment software environments. Training staff to use the software effectively and establishing clear performance metrics are essential for maximizing impact.
Summary
The continued rise in shipping, labor, fixed assets, and associated operational costs demands that online retailers, brands, and 3PLs that service them find innovative ways to optimize their financial health. One easy way to do that is to employ intelligent packaging design to reduce dimensional weight charges and oversized shipment surcharges resulting from inefficient packaging. Relying on manual processes or outdated shipping software label systems is no longer viable.
Additionally, the environmental impact of e-commerce operations is under greater scrutiny than ever. Customers expect fast and reliable delivery and appreciate thoughtful packaging that reflects a company’s commitment to sustainability. Cartonization software’s ability to ensure that packaging decisions align with these priorities, minimize waste, and reduce carbon emissions positions it as an essential tool for meeting these increased pressures. For online businesses looking to stay competitive and profitable, investing in this technology is not just a practical decision but a strategic imperative.

Up to 64% Lower Returns Processing Cost

Sustainable Ecommerce Returns: Why Sustainability Matters for Returns | Cahoot
In this article
9 minutes
- Why Sustainability and Environmental Impact Matters to Consumers
- Actual Authentic Sustainability Programs are Hard Work
- Understanding the Environmental Impact of Ecommerce
- Capturing the Attention of Eco-Conscious Customers
- Sustainability Programs Generate Profit and Customer Retention
- Strategies for Implementing ESG Programs and Other Sustainable Practices
- Strategies for Reducing Returns
- Efficient Returns Management Systems
- Sustainable Practices in Returns Management
- Overcoming Challenges
- Building Long-Term Customer Loyalty
- Frequently Asked Questions
As environmental consciousness becomes a core value for consumers, ecommerce brands and retailers are rethinking their strategies to align with eco-friendly principles. This shift in consumer behavior (~78% of shoppers now include sustainability in their purchasing decisions) allows businesses to adapt early and convert this eco-conscious market ahead of others. Understanding why sustainability matters to consumers can help brands get ahead of competitors and capture their attention sooner. This can grow market share through stronger customer relationships built on mutual ideals, leading to long-lasting loyalty and higher lifetime value. Implementing and effectively communicating sustainability initiatives to customers can further enhance trust and loyalty.
Why Sustainability and Environmental Impact Matters to Consumers
Modern consumers increasingly recognize their role in addressing global climate challenges, many more recently citing sustainability as an important factor in their purchasing decisions. This signals an unspoken evaluation of businesses based on their environmental commitments. It wouldn’t be surprising to learn that the Millennials, Gen Z, and higher-income demographics lead this charge, often willing to pay premiums for eco-friendly products. Their motivations stem from a blend of personal values, social pressure, and a desire to support businesses that contribute to a healthier planet. Or at least don’t detract from one. Sustainable ecommerce order shipping and returns, which minimize waste and carbon emissions while maximizing profitability and customer loyalty, are a key aspect of these sustainable practices.
It’s important, however, to be aware that there’s a healthy amount of skepticism regarding the sustainability claims made by businesses, as nearly 90% of consumers are wary of greenwashing (the practice of making false or misleading claims about environmental actions and/or benefits), demanding verifiable data and authentic actions from brands. This growing awareness highlights the need for transparency and the measurable and verifiable impact of business efforts on the ecosystem.
Actual Authentic Sustainability Programs are Hard Work
To capture the attention of eco-conscious consumers, businesses must demonstrate genuine commitment to sustainability. Encouraging customers to retain low-cost items during the returns process as part of a Green Returns Initiative can promote sustainability by minimizing waste and shipping, while also enhancing customer satisfaction and engagement.
Transparent reporting is essential, with brands needing to publish sustainability reports that include concrete metrics such as carbon emissions reductions or resource savings. Ethical sourcing and business practices, supported by certifications, enhance credibility. Innovative product design that incorporates recycled materials, upcycled products and/or reduced waste or reusable goods plays a crucial role in meeting eco-conscious expectations. Purpose-driven marketing should authentically communicate a brand’s sustainability mission, avoiding vague claims while focusing on genuine storytelling that connects emotionally with consumers.
Understanding the Environmental Impact of Ecommerce
The environmental impact of ecommerce is significant; online shopping contributes to increased carbon emissions, waste generation, and energy consumption. The rapid growth of ecommerce has raised concerns about the environmental impacts of online shopping, highlighting the need for sustainable practices. Online retailers must understand the specific environmental impacts of their operations to develop effective strategies for reducing their environmental footprint. By addressing these issues, businesses can not only mitigate their environmental impact but also appeal to eco-conscious customers who prioritize sustainability in their purchasing decisions.
Capturing the Attention of Eco-Conscious Customers
We know that eco-conscious consumers are discerning, seeking authenticity and actionable impact. So, brands that want to attract this segment must offer engaging experiences that connect with their values. Developing interactive campaigns or gamification elements that reward sustainable choices fosters even deeper engagement. Simple education and awareness play an essential role in helping consumers make informed decisions by providing accessible resources that explain the environmental benefits of their products. Collaborations with eco-friendly organizations or other sustainable brands amplify efforts and build credibility, further strengthening consumer trust.
While attracting attention is a vital first step, converting eyeballs into loyal customers or even proponents and brand evangelists requires addressing barriers such as cost and accessibility. Clear value propositions are essential, emphasizing the durability, quality, and long-term cost savings of sustainable products. Affordable options make sustainability accessible to a broader demographic than older and more financially stable shoppers. Sharing relatable stories about how initiatives have positively impacted the environment and communities shows the human impact to sustainability and nurtures emotional connections with the brand.
Sustainability Programs Generate Profit and Customer Retention
Sustainability has become a crucial marketing and revenue element of ecommerce, as consumers increasingly prioritize eco-friendly practices and environmentally responsible businesses. By embracing sustainable practices, ecommerce businesses can not only reduce their environmental impact but also cater to the growing demand for eco-friendly options.
This approach not only builds customer loyalty but also ensures long-term customer satisfaction and retention. As consumers become more eco-conscious, they are more likely to support brands that align with their values, leading to a competitive advantage in the market.
Strategies for Implementing ESG Programs and Other Sustainable Practices
Creating an Environmental, Social, and Governance (ESG) program and embedding sustainability into the core of business operations requires thoughtful planning and execution. Companies can start by optimizing supply chains, which include reducing emissions through efficient delivery routes, local sourcing, and consolidated shipments to reduce transportation cycles. Sustainable packaging that uses biodegradable or recyclable materials addresses consumer concerns about single-use plastics. Recycling programs such as H&M’s Garment Collecting Program incentivize customers to recycle used and unwanted apparel, contributing to a circular economy that benefits consumers and the planet.
Reducing the impact of ecommerce reverse logistics (product returns) on the environment is another way to support eco-conscious consumers. When optimized, a well-rounded Return and Exchange Program can play a profound role in reducing waste and conserving resources, allowing businesses to recover value from returned goods while minimizing environmental impact. For instance, establishing systems to inspect, refurbish, and resell returned items not only reduces landfill waste but also offers cost savings to consumers who are more than happy to accept a discounted “open box” item while also creating a new revenue stream for the retailer that may have otherwise contributed to revenue erosion.
Efficient reverse logistics strategies require careful planning and investment in technology and service partnerships. Brands can implement streamlined return processes that reduce emissions, such as consolidating shipments for returned goods or offering local drop-off points to minimize the impact of exhaust emissions from the repeated transportation of the same items back and forth between customers and processing facilities. Partnerships with next-generation returns programs specializing in hands-off and sustainable re-commerce solutions can further enhance these efforts. By integrating reverse logistics into their broader sustainability programs, brands and retailers demonstrate a holistic commitment to reducing their environmental footprint and delivering value to eco-conscious consumers.
Strategies for Reducing Returns
The best way to deal with returns is by not having any. Minimizing returns is crucial for reducing environmental impact as well as lowering operational costs. One effective strategy is providing comprehensive product information to manage customer expectations better. Detailed descriptions, high-quality images, and customer reviews can help shoppers make informed decisions, reducing the likelihood of returns.
Another approach is incentivizing customers to keep their purchases, which can reduce return rates. Offering discounts on future purchases or loyalty points can encourage customers to retain their items. Ensuring returned items are resold, donated, or recycled is also essential for reducing waste. By embracing these strategies, ecommerce businesses can lessen the environmental impact of returns and enhance customer satisfaction.
Efficient Returns Management Systems
Efficient returns management systems are crucial for enhancing customer satisfaction and streamlining operations. Implementing automated systems and tools can reduce the time and effort required for returns processing. Leveraging technology can empower ecommerce businesses to lower return rates and improve customer satisfaction. Focusing on boosting customer satisfaction through efficient returns processes is essential for building customer loyalty and retention. Considering sustainability in returns management practices is also vital for reducing waste and minimizing environmental impact. By optimizing inventory management and ensuring a seamless returns process, businesses can meet customer expectations while promoting eco-friendly practices.
Sustainable Practices in Returns Management
Sustainable practices in returns management are essential for reducing waste and minimizing environmental impact. Implementing a closed-loop supply chain can help in recycling returned products, minimizing landfill waste. Partnering with third-party logistics providers can efficiently handle returns and ensure items are put back into inventory. Offering boxless returns such as in-store returns allows for immediate inspection and restocking, reducing the environmental impact. Implementing reusable packaging and dunnage saves on return shipping costs.
Adopting these strategies can enable retailers to guarantee that returned items are resold, donated, or recycled, reducing waste and promoting sustainability. By integrating these sustainable practices, businesses can enhance customer satisfaction and loyalty while contributing to a healthier planet.
Overcoming Challenges
Despite the benefits of sustainability, businesses often face obstacles such as balancing profitability with the cost of such programs. Proving product quality is also a key step. Consumers need to believe in the performance and reliability of eco-friendly alternatives to counter misconceptions about their effectiveness. Lastly, consistent communication about the sustainability journey, including successes, setbacks, and future goals, is vital in building and preserving consumer trust.
Building Long-Term Customer Loyalty
The path to building an eco-friendly brand reputation and attracting loyal, eco-conscious customers lies in making sustainability a shared journey. Creating opportunities for customers to participate in meaningful actions, such as planting trees or donating to environmental causes through purchases, helps build a sense of community and purpose. Highlighting their contributions to the broader global sustainability objectives reinforces the customer’s connection to the brand and its mission. By prioritizing transparency, innovation, and authentic engagement, brands, and retailers can align themselves with consumer values, driving profitability and lasting impact and presenting a powerful opportunity to redefine success in an environmentally conscious world.
Frequently Asked Questions
Why are sustainable ecommerce returns important?
Sustainable eCommerce returns are important because they reduce environmental impact and enhance customer satisfaction by minimizing waste and promoting eco-friendly practices. This helps lower carbon emissions and create a positive shopping experience for customers.
How can ecommerce shipping be done sustainably?
Choose sustainable packaging such as biodegradable bags and packing peanuts. Use the right sized packaging. Have packaging be re-usable for returns.
How can ecommerce environmental impact be measured?
Regularly track metrics like carbon emissions associated with shipping and packaging to identify areas for improvement. Provide customers with accurate reports to show the business commitment and progress towards reducing carbon emissions and waste reduction.
Why is it important to have a sustainable return policy?
A sustainable return policy helps minimize environmental footprint by reducing waste and also reduces packaging costs for businesses.

Up to 64% Lower Returns Processing Cost

How to Optimize Reverse Logistics
Reverse logistics has emerged as a vital aspect of supply chain management in modern ecommerce, and its reach continues to expand. While it still includes the movement of goods from customers to retailers, it’s no longer limited to just handling returns. It encompasses customer communication and expectation setting, order and inventory management, repairs, recycling, resale, and recommerce and can have substantial revenue implications. With ecommerce return rates averaging 20–30% across categories, businesses must adopt innovative strategies to optimize reverse logistics to balance efficiency, profitability, customer relationships, loyalty, and sustainability. Implementing an effective reverse logistics strategy not only reduces operational costs but also enhances customer satisfaction while promoting sustainability efforts.
What is Reverse Logistics?
Reverse logistics refers to a specialized segment of supply chain management that focuses on the movement of goods from the customer back to the retailer or manufacturer. The process is initiated for various reasons, including product damage, seasonal inventory adjustments, restocking, salvage, recalls, or managing excess inventory. It crucially enables companies to regain value from returned products, reduce waste, and significantly improve customer satisfaction. By efficiently handling returns, businesses can enhance their overall supply chain performance and foster stronger customer relationships.
Reverse Logistics vs. Traditional Logistics
While traditional logistics involves the forward movement of goods from the manufacturer to the customer, reverse logistics focuses on the backward flow of products from the customer back to the retailer or manufacturer. The primary distinction between the two lies in the direction of product flow. Traditional logistics aims to ensure timely and efficient delivery of products to customers, optimizing the supply chain to meet demand. In contrast, reverse logistics deals with the complexities of retrieving products from customers, managing returns, and processing these items for resale, refurbishment, or disposal. This reverse flow is essential for managing returns efficiently, reducing waste, and maintaining customer satisfaction, making reverse logistics a critical component of modern supply chain management.
The Importance of Reverse Logistics
Reverse logistics has become a pivotal part of retail success, influenced by changing consumer desires and behavior. For example, well over 50% of online shoppers now report engaging in “bracketing,” the practice of purchasing multiple product variations to return those that do not meet their needs. This necessitates sustainability programs that mitigate the increased environmental considerations, as estimates put the carbon emissions related to reverse logistics near 25% of the total ecommerce footprint.
Returns management impacts operational costs and brand loyalty, as customers are significantly more likely to make repeat purchases following a retailer’s smooth returns experience. Clear and comprehensive return policies can significantly improve customer service by making the returns experience straightforward, providing a competitive edge in the market.
Optimized reverse logistics delivers numerous advantages, from enhanced inventory management and quick reintegration of resellable items, to streamlined processing for reducing operational expenses, to refurbishing and reselling non-new items to generate creative income streams where products might otherwise have gone to the landfill. Efficient returns handling software and processes build customer trust and loyalty, and proper recycling and waste management mitigate sustainability challenges.
What is the Reverse Logistics Process?
The reverse logistics process is multifaceted, involving several key components that work together to manage returns, reduce waste, and enhance customer satisfaction. These components include:
- Returns Management: This involves overseeing the return of products from customers, including processing refunds, exchanges, and repairs. Effective returns management ensures a smooth and hassle-free return process, which is crucial for maintaining customer satisfaction.
- Return Policy and Procedure (RPP): Establishing a clear return policy and procedure is essential. An effective policy should outline the rules and guidelines for returning products, ensuring that customers are well-informed and that the return process is consistent and transparent.
- Remanufacturing, Refurbishment, or Replacement: This involves repairing or replacing defective products or remanufacturing items to make them suitable for resale. By refurbishing returned products, companies can reduce waste and recapture value.
- Packaging Management: Managing the packaging of returned products is vital to minimize waste and reduce the environmental impact of returns. This includes using sustainable packaging materials and optimizing packaging processes.
- Unsold Goods: This component deals with managing unsold products returned from retailers or distributors. Strategies may include disposing of, recycling, or reselling these products to minimize losses and reduce waste.
- End-of-Life (EOL) Products: Managing products that have reached the end of their life cycle involves recycling, refurbishing, or disposing of these items responsibly. This component is crucial for sustainability and reducing the environmental footprint of returns.
- Delivery Failure: Handling failed deliveries involves re-routing or re-delivering products to customers. Efficient management of delivery failures ensures that customers receive their products promptly, maintaining customer satisfaction.
By understanding and effectively managing these components, companies can develop robust reverse logistics processes that optimize returns management, reduce waste, and enhance customer satisfaction.
Core Strategies for Optimization
1. Technology Integration: Integrating advanced technologies is key to streamlining reverse logistics operations and optimizing inventory management. Solutions include:
- Warehouse Management Systems (WMS), which enable real-time tracking and management of returns and exchanges, centralizing all customer communication, automating where possible, and creating and managing workflows for maximum efficiency.
- Inventory Management Systems (IMS) are used to authorize customer returns, return shipping, inspection, categorization, and resale/redistribution of returned goods.
- Implementing software systems that create efficient return and exchange workflows, enabling customers with a self-service portal and a consistent but straightforward process for making returns, requesting exchanges, and suggesting upsell and cross-sell items to retain revenue rather than providing full refunds. Employing robotic systems for sorting, inspecting, and storing returned items to remove as much of the human from the process as possible, decreasing the returns program’s overall cost.
2. Data-Driven Decision-Making: Closely analyzing data can provide valuable insights into returns management trends and help address root causes to prevent future returns. Retailers can:
- Capture and analyze the reasons for returns and fix the issues, such as manufacturing defects or inaccurate product descriptions, that are leading to mismatched customer expectations.
- Use returns data to improve product design and to design new products that align offerings with customer preferences.
- Use returns data to implement disposition rules that streamline returns processing to reduce the time to resale.
- Use predictive analytics to forecast returns and optimize inventory procurement.
3. The Importance of Sustainability: Environmental responsibility is an integral part of modern reverse logistics. Strategies include:
- Repairing/refurbishing and reselling returned items to minimize waste.
- Partnering with local organizations to recycle unsalvageable products.
- Investing in durable shipping materials to reduce packaging waste.
- Engaging in the circular economy and encouraging recommerce through platforms like ThredUp and Arrive Recommerce.
4. Customer-Centric Solutions: Prioritizing customer experience ensures loyalty and reduces friction. Retailers should:
- Offer multiple return options, including in-store returns, home pick-up, and drop-off points such as lockers.
- Implement a clear and transparent return policy and prominently display the details using simple website language.
- Offer printerless and boxless return solutions with easy-to-follow procedures.
- Provide regular status updates and quick refunds to reinforce trust and transparency.
5. Consolidation and Localization: Consolidating returns locally can significantly reduce costs and environmental impact by reducing the transportation burden. However, this is not a one-size-fits-all strategy. For example, high-value items, seasonal items, or those in high demand in a particular region should be sent directly to the store or warehouse most likely to resell or ship the item(s) quickly to maintain resale value.
6. Policy Development: Developing competitive yet viable return policies is essential for efficient supply chains. Key practices include:
- Implementing category-specific restrictions to manage expectations and costs.
- Setting clear guidelines for handling high-value items.
- Offering premium return and/or exchange services for VIP customers, such as free returns or bonus store credit for exchanges.
- Training staff to handle returns efficiently or partnering with specialized third-party logistics providers to outsource returns operations and minimize expenses.
Summary
Optimizing reverse logistics is no longer optional. It has become essential for thriving in today’s modern ecommerce landscape. Technological advancements and evolving consumer behavior patterns will shape its future. Retailers should explore innovations such as agentic artificial intelligence to create a more robust and personalized customer experience that operates 24/7/365. Blockchain technology can improve transparency and traceability within the supply chain. At the same time, collaborative platforms enable logistics solutions from outsourcing returns entirely to helping offload inventory through third-party recommerce channels. Businesses must also prioritize sustainability, integrating eco-friendly practices to meet consumer expectations, and it’s also just good citizenship. Balancing customer convenience with cost control will remain a central challenge, requiring continuous adaptation and investment in innovative returns solutions. A well-executed reverse logistics strategy minimizes costs, strengthens customer relationships, and reinforces a brand’s commitment to environmental responsibility.
Frequently Asked Questions
What is reverse logistics?
Reverse logistics refers to the process of moving goods from customers back to retailers or manufacturers for reasons such as returns, repairs, recycling, or disposal. It aims to regain value from returned products, reduce waste, and improve customer satisfaction.
How does reverse logistics differ from traditional logistics?
Traditional logistics focuses on the forward movement of goods from manufacturers to customers, while reverse logistics deals with the backward flow of products from customers back to retailers or manufacturers. Reverse logistics involves managing returns, refurbishing products, and reducing waste.
Why is reverse logistics important for ecommerce businesses?
Reverse logistics is crucial for ecommerce businesses as it helps manage returns efficiently, reduce operational costs, and enhance customer satisfaction. It also supports sustainability efforts by minimizing waste and promoting recycling and refurbishment.
What are some core strategies for optimizing reverse logistics?
Core strategies for optimizing reverse logistics include integrating advanced technologies, analyzing data for decision-making, prioritizing sustainability, offering customer-centric solutions, consolidating returns locally, and developing competitive return policies.

Up to 64% Lower Returns Processing Cost

UPS Announces Astonishing SurePost Rate Increases for 2025
UPS SurePost is a hybrid delivery service that integrates UPS’s network with USPS’s extended final-mile reach and capabilities. It’s a partnership between two competitors playing to each of their strengths to achieve greater cost efficiency, and it’s set to undergo notable changes in 2025. In particular, the primary benefit of SurePost, the lower cost of getting packages into the hands of their intended recipients, will see a substantial rate hike and service modifications in 2025, marking a profound shift in what ecommerce shippers have come to expect from the service. Understanding these developments is crucial for merchants to adapt their operations and optimize margins next year.
Key Changes to UPS SurePost Rates in 2025
Starting January 13, 2025, packages weighing 1 to 9 pounds will see a 9.9% price increase, while those weighing 10 to 70 pounds will increase 5.9 to 7.1%. Additionally, surcharges for deliveries to less densely populated areas will increase dramatically. The Delivery Area Surcharge (DAS) will rise 61.8% to $6.15, and the Extended Delivery Area Surcharge will climb a whopping 69.4% to $8.30. These changes reflect the broader trend of rising costs of last-mile delivery services.
In addition to these changes, the U.S. Postal Service will discontinue the allowance of dual shipping labels starting January 1, 2025, as it looks to increase its network’s efficiency and gain more direct customers for USPS Ground Advantage Services, which has a faster delivery SLA than SurePost by ~2 days on average. This will limit UPS’s package routing flexibility which currently allows them to decide which agency will deliver the package to the doorstep much later in the sortation workflow. Now, shippers must use labels that indicate the responsible final mile delivery agent when the package is accepted for processing.
Comparisons Across National Carriers
UPS’s SurePost fee changes align with what we see in the broader shipping industry. USPS will increase rates for its Parcel Select service by an average of 9.2%, depending on where the package enters the postal network, while its Ground Advantage service will rise by 3.2% for commercial accounts. FedEx is implementing various surcharges and rate adjustments, including a new $1.50 inbound processing fee, expanded fuel surcharges to include address correction and dangerous goods, and implementing their own DAS price increases. So, although UPS’s SurePost increases are significant, they reflect all the national carriers’ efforts to address rising operational costs and align pricing with market demands.
Implications for E-commerce Merchants
All shipping rate hikes pose challenges for e-commerce businesses, particularly those with razor-thin margins that rely on lower-cost carrier services to operate profitably. In many cases, the increased shipping costs trickle down to the consumer through higher pricing because online retailers cannot shoulder the entire burden. We may eventually observe altered consumer spending behavior, forcing Sellers to find new opportunities to reduce costs and return the business to healthy and sustainable margins.
Strategic Adjustments for Merchants
Several strategies could be employed to help reduce shipping costs:
- Shipping Cost Analysis and Carrier Negotiations: Conduct a detailed shipping cost analysis to identify order distribution across the product catalog and which SKUs, customers, regions, channels, etc., will contribute to increased cost. Use the data to adjust the carrier/service mix, matching delivery date promises with carrier/service SLAs and pricing. Identify opportunities to negotiate carrier contracts to reduce shipping costs in other areas, such as different package sizes, weights, variances, zones, and alternative delivery services, to minimize the impact of the new rate changes (or explore alternative carriers and services in particular, regional carriers that are trying to compete with the large national carriers to gain market share).
- Shipping Optimization: Leverage technologies such as next-generation shipping label software for AI-assisted rate shipping, automatically creating optimal shipping labels and optimizing fulfillment across inventory locations (in and out of the ‘network’).
- Free Shipping Adjustments: Retailers offering free shipping may either need to raise minimum order thresholds to balance customer expectations with the new financial realities or, as mentioned above, intelligently merge the new overall expected transportation cost into the complete product catalog pricing to minimize or offset the financial burden.
- Packaging Optimization: Review packaging (boxes, mailers) and void fill (air cushions, paper) pricing and optimize for smaller packages and less void fill where possible. Also, shift to less expensive padded mailers. Use intelligent cartonization software to pack shipments efficiently to reduce carrier shipping costs and packaging waste. Negotiate with packaging suppliers and consider taking larger deliveries less frequently or pre-buying supplies to take advantage of volume/commitment discounts.
Summary
As carriers adjust to ever-rising costs by updating their fee structures and passing costs on to their customers, e-commerce brands and retailers must also determine how to manage the rising costs by cutting elsewhere or passing all or part of the costs further to their customers.
The last-mile delivery space is continuously evolving as new solutions are brought to market and innovations applied to existing technologies and services continue to mature. There are a dozen prominent regional carriers that could help reduce shipping costs for some percentage of shipments. Or, consider partnering with fulfillment experts to distribute the high-volume inventory and capture meaningful margin savings by shipping orders from warehouses closer to the customer.
In any case, one thing is clear…costs continue to rise year after year, and the solution isn’t one-dimensional. To stay competitive and grow a successful online commerce business, there needs to be a fundamental shift in how e-commerce order fulfillment and reverse logistics are managed.

Up to 64% Lower Returns Processing Cost

Efficient Shippers Use Smart Cartonization Software to Save Big
Shipping costs are one of the largest cost centers for any e-commerce business and are second only to labor costs. With last-mile expenses increasing yearly, finding ways to reduce these costs is more important than ever. Leveraging technology to optimize shipping costs by right-sizing packaging can reduce shipping expenses significantly while improving operational efficiency and positively impacting the environment.
What is Cartonization Software and Parcel Packing Intelligence
One of the most effective ways to reduce shipping costs is to right-size the packaging. The reason is that shipping rates are based on weight. Still, shippers are charged the higher of the actual shipment weight (product in a box) OR the dimensional weight (the package volume in cubic inches turned into a weight value for rating purposes).
Efficient Shippers have reported saving over six figures just by right-sizing their packaging. Additional savings come from lower packaging costs from using less packaging. Further savings are achieved by reducing or eliminating dunnage required to fill the void in the larger box so items ship safely, less tape is used, etc.
The average return rate for ecommerce orders is in the 15 to 30% range (much higher for apparel); right-sizing the packaging would also reduce the cost of return shipping when the original packaging can be re-used for reverse logistics.
Cartonization software (or smart cartonization features built into Order Management Systems or Multi-Carrier Shipping and Fulfillment Software such as Cahoot) can help automate selecting the best packaging for each order, even for complex shipments containing multiple product and quantity configurations. For example, Cahoot software evaluates the dimensions of the items being shipped and auto-selects the smallest box the products can safely ship in from a list of available options in stock. By using cartonization capabilities prebuilt into software like Cahoot, ecommerce merchants can ensure they are shipping orders in the most cost-effective packaging rather than relying on warehouse staff members to guess the correct size. No human means no judgment is needed, and human errors are eliminated.
A crucial part of parcel packing intelligence, i.e., right-sizing shipments is to stock a wide variety of box, non-corrugate packaging and mailer sizes. Many shippers only stock a limited range of packaging sizes, which forces them to use larger boxes when smaller ones would suffice. Expanding the available box sizes can reduce the risk of paying to ship a lot of air. Some shipping and fulfillment solutions even support the tracking and management of packaging inventory, including cost, reorder points, etc.
It’s worth noting that cartonization and packing tools are useless without accurate dimensional data. Easy AI-based tools such as the Qboid M2 Perceptor Mobile Dimensioning handheld device have recently become available, making capturing these details a breeze.
Increase Sales and Profits through Cartonization Software
For Sellers that can pass shipping costs to their customers, right-sizing packaging increases profits and conversions through more competitive ‘all-in’ product pricing, leading to higher revenues.
Reduce Waste using Smart Cartonization
While used cardboard boxes can be recycled, much of it still ends up in a landfill with a negative environmental impact and a higher carbon footprint. So, right-sizing shipping supplies also helps the planet.
The best way to minimize cost and environmental impact is not to use overpacks at all – ship the items in their original manufacturer packaging. Amazon’s SIPP program (Ships in Product Packaging) was opened to Amazon FBA Sellers in early 2024 to reduce costs and improve sustainability. It’s generally been regarded as successful.
It’s recommended to collaborate with suppliers to design product packaging to optimize for shipping costs, staying away from the surcharges carriers impose on “oversize” shipments.
Dimensional Weight
As mentioned above, DIM weight considers the package’s volume, meaning large boxes, even when filled with light products, can incur substantial shipping charges.
The DIM weight is calculated by multiplying the package’s length, width, and height, then dividing by a DIM factor set by the carrier. FedEx and UPS typically use a DIM factor 139 for domestic US shipments, while the USPS uses 166. The higher the DIM factor, the more “air” you can include in a package before triggering the DIM weight pricing.
For example, if you use a 12″x12″x12″ carton, it will be billed as a 13-pound package by UPS and FedEx based on its volume, even if the actual contents weigh much less (a box of cotton candy, as an extreme example). Over time, these minor discrepancies can add up to thousands of dollars in extra shipping fees. Switching to smaller cartons that more appropriately fit your products can help reduce these DIM weight charges. It also minimizes the need for excess void fill, such as bubble wrap or packing peanuts, which adds cost and waste to each shipment.
An example:
Shipping this 2.25 lb product 8 zones in a slightly larger box than the product (8 x 5 x 5) will cost $9.52 using USPS Ground Advantage. Shipping this 2.25 lb product 8 zones in an adequately fitted box (8 x 5 x 3) will only cost $8.35 using USPS Ground Advantage. This is only 2 inches longer on one side but represents 40% air (200 cubic inches vs. 120 cubic inches). That’s over 12% savings on just one shipment and not that egregious of an example. And not including all the waste saved as described above.
Summary
Reducing operations expenses must be a forethought to achieve continued business success. By utilizing technology like cartonization software to optimize shipment packaging, not only are shipping cost savings guaranteed, but the cost of the supplies goes down, operational efficiency goes up, and more sustainable business practices not only result in lower carbon emissions and less waste but it can also enhance brand reputation.
Amazon’s New Shipping & Delivery Policies, Key Changes and Their Implications
In this article
6 minutes
Amazon continues to set the pace for customer satisfaction and delivery expectations. As we approach the latter half of 2024, Amazon is rolling out significant changes to its shipping and delivery policies that will impact Sellers across the platform. These updates aim to enhance the customer experience by ensuring faster, more accurate delivery times while also providing tools and guidance for Sellers to meet these new standards. Let’s dive into the key changes and what they mean for Amazon Sellers.
The Importance of On- Time Delivery
Amazon’s focus on fast and accurate delivery is not new, but it’s becoming increasingly important to the marketplace operator. It’s well known that the delivery speed and reliability of the delivery date expectation set during checkout are major factors in customers’ purchasing decisions. To meet this expectation, Amazon will be rigorously enforcing a new on-time delivery rate (OTDR) policy that will directly affect Sellers’ ability to list products on the marketplace.
Starting September 25, 2024, Sellers will need to maintain a minimum 90% OTDR without promise extensions to continue listing seller-fulfilled products on Amazon.com. This policy change underscores the importance of reliable shipping practices and puts the onus on Sellers to meet customer expectations. For optimal performance, Amazon recommends maintaining a 95% or higher OTDR for all seller-fulfilled orders.
It’s worth noting that this policy doesn’t apply to Fulfillment by Amazon (FBA) orders where Amazon is responsible for meeting delivery promises. However, for Sellers managing their own fulfillment, this change could have significant implications.
Updates to Transit Time Settings
To help improve OTDR and the reliability of delivery date promises made to customers, Amazon is reducing the number of transit days allowed for both Standard and Free Economy shipping options in shipping templates.
Some Sellers may have already noticed an update to the transit time requirements which became effective August 25, 2024. For Sellers shipping from the continental United States (excluding Hawaii, Alaska, and US territories), the maximum transit time allowed for Standard Shipping has been reduced to 5 days, while Free Economy shipping will have a maximum of 8 days.
There’s an important caveat for media items such as books, magazines, and DVDs. These products will continue to have a maximum transit time of 8 days for Standard Shipping. Sellers should pay close attention to their product categories to ensure compliance with these new transit time limits.
For those offering Free Economy shipping, Amazon has already adjusted max transit times in shipping templates from the previously allowed 5 to 10-day range to the new 4 to 8-day requirement. While no action is required from Sellers, they continue to have the option to disable Free Economy shipping if they prefer not to offer this service within the new timeframe.
Introduction of Automated Handling Time
Perhaps the most significant change for many Sellers will be the introduction of Automated Handling Time (AHT), set to take effect on September 25, 2024. AHT will use historical shipping data to set more accurate handling times for each SKU based on how long a Seller has typically taken to ship it in the past. For new products without historical data, AHT will default to the manually configured handling time.
This automation aims to provide customers with faster and more accurate delivery date estimates, potentially leading to increased sales for Sellers. However, it also means that Sellers will need to consistently meet these handling time expectations to maintain an acceptable OTDR. AHT will automatically take Order Handling Capacity into account (the maximum number of orders that have been fulfilled in the past 90 days) and adjust delivery promises to reflect longer handling times accordingly; the objective is to avoid overburdening Sellers with shorter handling times that cannot be met.
This feature will be automatically enabled for Sellers who currently have a handling time gap of 2 days or more compared to their actual shipping performance (Sellers can find their current handling time gap here). AHT is already available in the Order Handling Settings for Sellers that want to test how the new setting will affect their fulfillment workflows in advance of the September 25th obligation.
It’s important to note that handling time only considers business days, excluding weekend days unless weekend operations are intentionally enabled in Order Fulfillment settings.
AHT for Seller Fulfilled Prime Orders
For Prime orders that have one-day or two-day delivery expectations, the same-day handling time will continue to apply. Prime orders with standard delivery will default to a one-day handling time, unless a same-day default handling time is configured at the account-level, in which case, Prime orders with standard delivery would have a same-day handling time.
Exceptions and Protections
Amazon recognizes that certain products, such as custom-made and/or personalized items, certain media, and heavy or bulky goods, may require more flexible handling times. Sellers can request exceptions for these types of SKUs, allowing them to set manual handling time overrides. However, it’s important to note that exempted SKUs will not receive OTDR protection from late deliveries. OTD protection will be available to provide a safety net for Sellers as they adjust to the new policies.
To qualify for OTDR protection, Sellers must meet three conditions:
- Have Shipping Automation (SSA) enabled on the relevant shipping template. SSA helps set accurate delivery dates through automated transit time calculations based on preferred shipping services. (Learn More)
- Have AHT enabled on their account. (Learn More)
- Purchase “OTDR protected” Standard Shipping services through Amazon Buy Shipping
Preparing for the Changes
With these significant updates, Sellers should take proactive steps to prepare:
- Review current shipping practices and identify areas for improvement.
- Get familiar with the new transit time and handling time requirements.
- Consider enabling Automated Handling Time if it’s not already active to analyze how the required changes will impact business operations and workflows before the September 25th deadline.
- Evaluate product catalogs to determine if any items might qualify for handling time exceptions. Contact Seller Support and request that a ticket is created to have Handling Time exceptions applied to the list of SKUs.
Looking Ahead
Meeting customer expectations for fast and reliable order delivery is more crucial than ever. Amazon’s new policies reflect this reality, pushing Sellers to optimize their fulfillment processes or risk losing visibility on the marketplace. While these changes may present challenges, they also offer opportunities for Sellers to streamline their operations and potentially increase sales through improved delivery promises. Staying informed and continuously monitoring performance will help Sellers to ensure continued success on the Amazon marketplace.
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Up to 64% Lower Returns Processing Cost

Cahoot and Manifest Peer into the Future of eCommerce Order Fulfillment
In the lead-up to Manifest 2022, the leading conference focused on innovation in logistics and supply chain, Conference Chair Pam Simon is sitting down with leaders that are redefining what’s possible.
One of those leaders is our own Manish Chowdhary, who sat down with Pam to talk about the future of eCommerce order fulfillment. Cahoot, recognized as one of the World’s Most Innovative Companies in 2021, is empowering eCommerce merchants to offer fast and free delivery to their customers with a unique peer-to-peer platform.
The Power of Many: The Case for Ecommerce Fulfillment Networks
Demand for eCommerce order fulfillment will continue to grow
The changes in shopping behavior brought by COVID are here to stay (and then some), says Manish. eCommerce sales grew an incredible 44% year-over-year from 2019 to 2020, pulling forward many years of demand. Far from reversing, though, 2021 is projected to see another 18% jump over 2020.
Online sales growth, and thus demand for eCommerce order fulfillment, was primarily being driven upwards slowly and steadily by generational change prior to COVID. The pandemic, though, forced those that weren’t inclined to shop online to do so – and they discovered that they liked it. At the same time, companies large and small made enormous investments in multichannel order fulfillment, further increasing the convenience and ease of online shopping. Curbside pickup, same-day delivery, and vastly improved shopping portals are all here to stay, along with customer behavior.
How can merchants future-proof their eCommerce order fulfillment?
Don’t end up like Macy’s. Manish relates the story we all know now,
“In the 70’s, 80’s, and even 90’s, the Macy’s of the world went and built tons of buildings, got tons of leases, and then the consumer behavior changed. Those very assets that were helping them expand and grow became a liability.”
Big merchants that take the traditional approach of investing heavily in buying & building warehouses across the country tie up significant capital and run the risk of choosing the wrong locations. Moreover, warehouse space and personnel have never been more expensive – warehouse space is at an all-time low, and there are an incredible 400,000 open job positions for frontline eCommerce order fulfillment workers. A mid-size merchant that builds a second fulfillment center in a sub-optimal location will have the worst of all worlds – they still won’t be able to cover enough of the country with 2-day shipping, and their capital will be tied up in expensive real estate.
Outsourcing fulfillment to a provider like Cahoot, on the other hand, enables merchants to offer an Amazon-like delivery experience while keeping costs low. Customers expect fast and free shipping, and on top of that, Amazon keeps raising the bar for what ‘fast’ means. A distributed US fulfillment center network like Cahoot strategically deploys its customers’ inventory in multiple nodes across the country and can offer 99% 2-day and over 40% 1-day coverage. This level of service, in fact, enables Cahoot to provide Seller Fulfilled Prime (SFP) to its customers – something very few other 3PLs even attempt.
Critically, Cahoot has dozens of fulfillment nodes, so as customer demand and needs shift, it can instantly shift its customers’ fulfillment profiles to match. Some merchants are familiar with the pain of signing up with a 3PL to extend their reach – only for sales to grow in a different part of the country, and to be back at square one. Cahoot’s eCommerce order fulfillment network has redundancy across the entire United States, and it solves present and future fulfillment needs for its clients.
What does Cahoot do differently to future-proof eCommerce order fulfillment?
Every other order fulfillment network is constrained by the warehouse and labor shortage – but not Cahoot. Cahoot is a first-of-its-kind peer-to-peer order fulfillment network that enables merchants to fulfill orders for one another. This ingenious design solves the capacity crunch by unlocking latent warehouse capacity and monetizing it for the fulfilling merchant.
The idea was born out of ecommerce sales research. While looking at order profiles for a different project, Manish and his team realized that merchants on opposite coasts were selling identical products to people on the other coast. That is, a merchant in LA would sell a widget to a customer in NYC, and a merchant in NYC would sell the exact same widget to a customer in LA. They’d then both ship the product across the country – what a waste! This inefficient process hurt growth with slow deliveries, ate margins with long deliveries, and hurt the environment with extra emissions. Cahoot was born to help merchants solve this issue.
It quickly grew to be more flexible and inclusive – any merchant with an excellent warehouse can fulfill orders for any other merchant, regardless of what’s being sold. In fact, Cahoot’s intelligent platform and shipping software optimize each and every label printed to ensure that a product ships from the lowest-cost warehouse that will offer a speedy delivery.
Find us at Manifest 2022
On January 25-27th, 2022, Manifest will bring together the most comprehensive ecosystem of innovation and transformation in LogisticsTech and end-to-end Supply Chain. We’ll be there, talking about the future of eCommerce order fulfillment with anyone and everyone! Come find us – we’d be happy to see you.
Offer 1-day and 2-day shipping at ground rates or less.
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