Why and How to Use Discreet Packaging for Shipping

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You’d be surprised how many awkward customer support tickets start with a simple failure to ship discreetly. Over the past eight years, working with ecommerce merchants across every category you can imagine, health, wellness, fashion, adult products, I’ve seen one constant: customer privacy is a make-or-break issue. The right product packaging plays a crucial role in maintaining privacy and preventing potential embarrassment for customers, especially when shipping sensitive or personal items.

Discreet packaging isn’t just about avoiding embarrassment. Potential embarrassment is a key reason customers value discreet packaging, as it helps protect their confidentiality. It’s about trust, brand perception, and meeting rising consumer expectations around security, personalization, and sensitivity. Discreet packaging also helps maintain privacy for sensitive purchases, reducing the risk of theft and ensuring customer security. Whether you’re shipping prescription medications, high-value items, or personal care items, how you package and label the order can affect repeat business, returns, and even your ability to advertise.

Let’s break down what discreet shipping really means today, why it’s growing in importance, and how you can implement it without slowing down your fulfillment ops.

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What Is Discreet Packaging, Really?

At its core, discreet packaging refers to plain, unmarked packaging (often using plain boxes) that hides the nature of the product inside. But it’s more than just using a plain box; it’s a combination of:

  • Neutral packaging materials: No logos, product names, or category clues
  • Generic return addresses: Often using something like “Shipping Department” or a fulfillment center location
  • No branded tape or inserts: No flyers, product visuals, or “thank you” cards that hint at contents
  • Label anonymization: Avoiding descriptive product names in the shipping label or tracking info
  • Neutral labeling: Using vague, unbranded labels and generic descriptions to conceal package contents
  • Opaque outer containers: Especially important for sensitive items like incontinence products, adult toys, or medications

When done right, discreet packaging ensures that no one—neither the mail carrier, nosy neighbors, nor accidental family members—can tell what was purchased just by looking at the box. The package contents remain fully concealed for privacy and confidentiality.

Who Needs Discreet Packaging?

Short answer: more brands than you think. Many businesses and companies, especially ecommerce businesses, benefit from discreet packaging to protect customer privacy, build trust, and enhance the overall experience. Here’s where we see discreet packaging being not just nice-to-have, but critical:

Health & Wellness

This includes everything from prescription medications, medical devices, medical supplies, and health products to incontinence products and CBD oils. Patients don’t want the contents advertised on their porch. HIPAA compliance may not require discreet packaging directly, but the spirit of it absolutely supports it.

Adult Products

The most obvious use case. No one wants a box labeled “PleasurePro” showing up at their front door. Successful adult ecommerce brands build their entire customer experience around discretion, and their discreet shipping options are often highlighted on product pages and ads.

Personal Care

Even things like hair regrowth serums, skincare for acne, and certain sensitive products trigger embarrassment, making discreet purchasing and packaging especially important to customers. Consumers appreciate when a brand respects their desire to keep those purchases private.

Jewelry and Luxury

Beyond privacy, discreet packaging also protects against theft. Using plain packaging for high-value items such as jewelry, luxury goods, and electronics avoids drawing attention during transit, especially in high-theft metro areas.

Gift Purchases

Many customers order gifts and don’t want the recipient to see what’s inside early, as preserving the element of surprise is essential for a memorable gift-giving experience. Using discreet packaging materials can help reduce spoiled surprises and maintain control over the unboxing experience.

Why Discreet Shipping Is a Growth Lever

This isn’t just about reducing awkward moments. With the growing popularity of discreet shipping, driven by increased privacy concerns and the rise of unboxing trends, understanding why it’s growing in importance is crucial. When I work with merchants who implement discreet packaging correctly, they consistently report:

  • Higher customer satisfaction: Customers feel respected. That’s a powerful loyalty driver.
  • Fewer returns and chargebacks: People are less likely to return or dispute sensitive items when they arrive in a way that protects their privacy.
  • Increased repeat business: Especially in health and adult categories. Trust builds long-term customer value.
  • Better email deliverability: Discreet shipping claims in marketing copy can boost open rates, just don’t overpromise what you can’t operationalize.
  • Stronger brand reputation: Reviews often cite “arrived discreetly” as a reason for a 5-star rating.
  • Building trust with customers: Discreet packaging and shipping practices help establish a trustworthy relationship by maintaining confidentiality, especially for sensitive or personal items.

So to sum it up: a positive fulfillment experience, including discreet packaging, not only enhances customer satisfaction but also builds loyalty and confidence in your brand.

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Common Mistakes to Avoid

You’d be surprised how often brands check all the discreet packaging boxes, and then blow it on something small. Here are a few real mistakes I’ve seen:

  • Branded packing slips: Even if the box is plain, a label that says “MemorySupplementsNow.com” tells the whole story. Always use the company’s legal name, not a branded name, on return addresses and customs forms to maintain discretion.
  • External return addresses with brand names: Even if the box is plain, a label that says “MemorySupplementsNow.com” tells the whole story. Always use the company’s legal name, not a branded name, on return addresses and customs forms to maintain discretion.
  • Inconsistent warehouse practices: If your 3PL or fulfillment team isn’t aligned on your packaging SOPs, you’ll have one box go out perfectly and the next with tape screaming your brand name.
  • Carrier service level confusion: Some carriers auto-require an adult signature based on package type or origin, without notifying the shipper. That can backfire if a family member answers the door.

At Cahoot, we’ve had to help multiple brands unwind issues like this and re-train fulfillment partners. Privacy is only as strong as the weakest label. Consistency in shipping and packaging practices is essential to avoid privacy breaches and protect customer trust.

How to Implement Discreet Packaging the Right Way

Here’s the blueprint I’ve seen work across dozens of high-growth ecommerce brands that opt for discreet packaging solutions to protect customer privacy and reduce theft:

  • Map your customer journey and identify every touchpoint where packaging is seen or handled.
  • Audit your current packaging for branding, privacy, and sustainability.
  • Choose packaging materials and configure shipping labels to ship products discreetly, use plain, unbranded boxes or envelopes, and avoid revealing information on the exterior to maintain confidentiality.
  • Leverage ecommerce platforms to automate and support discreet packaging processes, ensuring accuracy and privacy throughout order fulfillment and delivery.
  • Test your packaging with real customers and gather feedback for continuous improvement.

Knowing why discreet packaging matters is only half the equation; the real magic is in how you operationalize it. Here’s how to turn that intent into a repeatable, scalable practice that protects your customers and your brand.

1. Define Your Level of Discretion

There’s a spectrum. Some brands need total discretion, even generic outer box codes. Others just need to avoid overt branding. Document your expectations clearly and audit them regularly.

2. Choose the Right Packaging Materials

Use standardized boxes in neutral tones (brown, white, or gray). Avoid glossy finishes, stickers, or anything that hints at a product category. Avoid transparent envelopes for obvious reasons.

3. Configure Shipping Labels Carefully

Work with your 3PL or shipping software to use a generic return address, a generic company name, and vague product descriptions. Never include product names like “testosterone kit” or “adult gift set” in the visible label metadata.

4. Align Fulfillment Teams

Whether you ship in-house or through a fulfillment center, document your discreet packaging policies in your SOPs. Add spot checks and audit frequently—trust but verify.

5. Offer Customers a Choice

Not everyone needs discretion, but those who do really do. Consider giving customers a checkbox at checkout: “Please ship in discreet packaging.” This also lets you reserve your branding for customers who don’t mind.

6. Communicate Transparently

If you advertise discreet shipping options, be very clear about what that means. Include sample photos. Avoid vague claims that might lead to chargebacks if expectations aren’t met.

7. Localize Where It Matters

In some regions, discreet packaging legal requirements exist. If you’re shipping to the EU or Canada, check compliance rules around what information must be included externally (like return info, customs declarations, etc.).

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The Sustainability Angle

This is where brands get stuck: “If we remove branding and custom packaging, do we lose our unboxing wow factor?”

Not necessarily. In fact, plain packaging can signal eco-conscious values, minimalism, and even premium quality, if you frame it correctly.

Some Cahoot merchants include a QR code inside the box that links to a branded unboxing video or “thank you” message. That lets them keep the external packaging plain while still creating a premium feel.

Plus, many discreet packaging materials double as recyclable or compostable. So if you’re thinking long-term about brand sustainability and shipping costs, discreet packaging actually gives you a win-win.

When Discreet Packaging Goes Wrong

Let me share a quick story: A men’s wellness brand I worked with had a viral campaign, but their warehouse kept forgetting to override default packing slips. Customers started posting photos of the box and the item name printed on the slip, “Testosterone Gel, 3-month supply.”

Cue negative reviews, awkward conversations, and a quiet hit to repeat revenue. It wasn’t the product—it was the failure to protect customer privacy that cost them.

When you lose a customer’s trust over something as easily preventable as packaging, it stings. And it’s avoidable.

Frequently Asked Questions

What does discreet packaging mean for ecommerce?

Discreet packaging means the package gives no visible clue about what’s inside. That includes using unmarked boxes, generic shipping labels, and no logos or brand names on the outside. It helps protect customer privacy and prevents unwanted attention.

Which products should use discreet shipping?

Products like prescription medications, adult items, personal care products, and luxury goods benefit from discreet shipping. Any purchase that could cause embarrassment or theft risk qualifies.

How do I discreetly ship items from my online store?

Use plain packaging with no branding, vague or coded product descriptions on shipping labels, and a generic return address. Make sure your fulfillment center follows these guidelines consistently.

Does discreet packaging affect shipping costs?

Not directly, unless you choose heavier or custom packaging. However, standardized boxes often reduce dimensional weight fees and help protect high-value items, which can lower loss-related costs.

Can I still offer a branded experience with discreet packaging?

Yes. You can include QR codes, branded inserts inside the box, or custom emails after delivery. The key is to keep the outside of the package neutral while still delighting the customer post-purchase.

Written By:

Indy Pereira

Indy Pereira

Indy Pereira helps ecommerce brands optimize their shipping and fulfillment with Cahoot’s technology. With a background in both sales and people operations, she bridges customer needs with strategic solutions that drive growth. Indy works closely with merchants every day and brings real-world insight into what makes logistics efficient and scalable.

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PONY UP Act: USPS Could Be Paying for Late Deliveries

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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).

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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.

Written By:

Jeremy Stewart

Jeremy Stewart

Jeremy Stewart leads customer success at Cahoot, helping merchants achieve high-performance logistics through smart technology and process optimization. With a background in both ecommerce operations and client services, Jeremy ensures that every merchant using Cahoot gets measurable results—whether they’re scaling from one warehouse to many or managing complex returns.

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2025 NMFC Changes for LTL Freight Shipments (Improved Classification)

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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:

  1. 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.

  2. 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.

  3. 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.

  4. 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.

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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.

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Preparing for the Transition

To prepare for these changes, organizations should:

  1. Train Personnel: Educate staff on density calculations and measurement techniques. Providing training in advance will help reduce errors.

  2. 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.

  3. Assess Current Shipping Pricing: Evaluate historical shipment pricing and contact carriers to identify areas where the updated density-based classifications might affect pricing.

  4. 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.

Written By:

Jeremy Stewart

Jeremy Stewart

Jeremy Stewart leads customer success at Cahoot, helping merchants achieve high-performance logistics through smart technology and process optimization. With a background in both ecommerce operations and client services, Jeremy ensures that every merchant using Cahoot gets measurable results—whether they’re scaling from one warehouse to many or managing complex returns.

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UPS Announces Astonishing SurePost Rate Increases for 2025

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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.

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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:

  1. 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).

  2. 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’).

  3. 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.

  4. 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.

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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.

Written By:

Rinaldi Juwono

Rinaldi Juwono

Rinaldi Juwono leads content and SEO strategy at Cahoot, crafting data-driven insights that help ecommerce brands navigate logistics challenges. He works closely with the product, sales, and operations teams to translate Cahoot’s innovations into actionable strategies merchants can use to grow smarter and leaner.

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Efficient Shippers Use Smart Cartonization Software to Save Big

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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.

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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.

Written By:

Rinaldi Juwono

Rinaldi Juwono

Rinaldi Juwono leads content and SEO strategy at Cahoot, crafting data-driven insights that help ecommerce brands navigate logistics challenges. He works closely with the product, sales, and operations teams to translate Cahoot’s innovations into actionable strategies merchants can use to grow smarter and leaner.

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