Every business decision impacts your bottom line—including packaging choices that are often overlooked. From selecting inappropriate materials to underestimating lead times, seemingly minor packaging missteps can lead to substantial financial losses, damaged products, and dissatisfied customers. This guide examines five common packaging mistakes that drain profits and offers practical solutions to help your business avoid these costly pitfalls while maximizing efficiency and customer satisfaction.
Strategic packaging decisions can significantly improve your business profitability
Packaging impacts more than just aesthetics—it affects your margins, shipping costs, customer experience, and more. Even experienced operators can fall into traps like using the wrong resin or failing to account for seasonal lead times.
Let’s break down five of the most common packaging mistakes we’ve seen at ePackage Supply, and what you can do to prevent them from eroding your profits.
Mistake #1: Choosing the Wrong Material or Resin
As Kyla Long, a seasoned packaging expert at ePackage Supply, explains: “Choosing the wrong material or resin can have disastrous consequences.” For example, using polypropylene for a frozen product could cause containers to crack during use—leading to product loss, reputation damage, and customer churn.
Solution: Work with a knowledgeable packaging partner like ePackage Supply who can guide you in selecting the right materials for your product and its intended use.
Mistake #2: Not Planning for Lead Times and Shipping Times
Underestimating lead times is one of the most common (and costly) packaging errors. “I just had somebody email me the other day saying, ‘I lost money today because my shipment didn’t arrive in time,’” says Kyla. “Well, they had ordered it three days before they needed it.”
Solution: Choose a supplier with transparent timelines and warehousing options to buffer inventory. At ePackage Supply, we help businesses plan ahead so they’re never caught off guard.
Quick Tip: Order packaging 2–3 weeks before you need it—especially around peak seasons or holidays—to reduce the risk of delays.
Mistake #3: Not Testing with the End Application
Even if your packaging looks great on paper, it may not hold up in real-world scenarios. A common issue: standard snap-on lids popping off during transit due to pressure changes, vibration, or mishandling.
Testing your packaging through its entire life cycle—from storage and shipping to final delivery—ensures it performs as expected in every condition.
Solution: Test packaging with your actual product and shipping method. Our team at ePackage Supply can help evaluate performance and recommend more robust alternatives if needed.
Mistake #4: Not Determining the Right Packaging Size
Selecting packaging based solely on weight can result in wasted space or worse—leakage. “Five pounds of rocks and five pounds of feathers are two way different volumes,” says Kyla. Volume matters just as much as weight when it comes to shipping costs and product protection.
Solution: Match container dimensions to your product’s true volume. Our sizing experts at ePackage Supply will help you choose the most cost-effective option.
Mistake #5: Neglecting Branding
Your packaging isn’t just a container—it’s a visual ambassador for your brand. Skimping on design can lead to missed opportunities for customer recognition, storytelling, and shelf appeal.
If your packaging looks generic or unclear, customers may forget your product or confuse it with competitors.
Solution: Elevate your packaging with decoration options from ePackage Supply, including dry offset, in-mold labeling, heat transfer labels, and more.
Professional packaging enhances perception and builds long-term brand loyalty
Calculate the True Cost of Packaging
Packaging costs go far beyond the unit price. You also need to consider:
- Storage and warehousing fees
- Shipping efficiency (space, weight, damage)
- Brand value and customer perception
- Spoilage or product loss from inadequate containers
- Environmental disposal or recycling costs
While calculating these costs precisely can be difficult, partnering with the right supplier can help you reduce and track these variables over time. At ePackage Supply, we work directly with businesses to help them understand their true packaging ROI.
“Smart packaging choices aren’t just about protection—they’re about profitability. You’re investing in your customer experience, logistics performance, and long-term growth.”
Paul Saunders, Packaging Expert
Ready to optimize your packaging strategy and boost your bottom line? Contact us today and discover how our expert team can help you reduce costs, increase efficiency, and deliver better packaging experiences for your customers.
Optimize Your Packaging Strategy
Avoid costly mistakes and maximize efficiency with our expert packaging solutions.
