Using the right packaging for oddly shaped items is crucial to protecting them from damage during shipping and handling. It also helps reduce waste and customer dissatisfaction.
Since these products have a more unique configuration compared to standard packaging, they need extra attention during packaging and shipping. This guide explores what makes irregular products unique, 10 common packaging mistakes and the best packaging practices and strategies for irregularly shaped products.
Understanding Irregular Product Packaging
Irregular products are items with atypical shapes and sizes that do not fit into standard square or rectangular packaging dimensions. These items may also include fragile or delicate components that require additional protection and careful handling.
A challenge of packaging and shipping these items is the excess space and increased shipping costs associated with oversized packaging. Additionally, since these items are more challenging to secure, there may be an increased risk of item damage.
These challenges make it essential to find tailored packaging solutions to help ensure that your irregularly shaped products reach their destination safely and in good condition. These solutions conform to your item’s irregular shape, minimizing the need for excessive packaging materials.
10 Common Irregular Product Packaging Mistakes to Avoid
Let’s explore some prevalent packaging mistakes and how to package irregular-shaped products correctly.
1. Using Standard Boxes for All Products
Using standard boxes for irregular products may provide inadequate securement and cushioning. This may lead to marks, breakage and internal product damage. Customers may also dislike oversized packaging because it is challenging to carry and generates unnecessary waste. Custom-sized or adjustable packaging solutions may reduce damage risks because they incorporate appropriate protection, such as custom layers, wrapping and extra padding to fill up hollow areas.
2. Inadequate Cushioning
Another issue is using the wrong type of cushioning materials or too little cushioning to adequately protect the product. When damage occurs in these situations, it may lead to increased returns and customer dissatisfaction. This makes it important to carefully assess the dimensions and fragility of the product. You can then choose packaging materials that will offer sufficient support, cushioning and barrier protection throughout transportation.
3. Over-Packaging
Avoid overpacking your boxes with products and adding excessive layers of filler that add little protection. This may cause products to rub or knock against each other during transport, and overstuffing the box with filler may increase shipping costs due to heavier weight. Find a balance between protection and efficiency by using a custom-sized box that uses less space or custom cushioning to protect items effectively.
4. Ignoring Product Orientation
The product’s orientation and shape often affect its stability and protection. Identify the item’s weak points and reinforce them with protective materials and additional padding. This helps ensure the product is securely nestled in the package to prevent shifting during transportation.
5. Not Accounting for Shipping Conditions
During shipping, your packaging and the items inside will experience various environmental and handling conditions. The package may endure moisture, hot temperatures, dust, dirt, rough handling and possible sliding and bumping against other boxes during transportation. The wrong packaging materials may result in damage to the package and product.
Choose packaging materials that can withstand different shipping environments. Work with a packaging company that has had its materials tested for durability against heat and moisture and cushioning that can keep products secure inside the packaging.
6. Failing to Use Protective Seals and Wraps
It’s important to check that seals, wraps and tapes can effectively secure irregular products. Incompatible seals may increase the risk of damage, tampering and exposure to the elements. Evaluate the strengths of the different types of protective seals and tapes, and use one that can effectively protect your product.
For example, hot melt tape has three layers and is durable, making it suitable for storing, shipping and sealing heavy boxes. Other options might include water-activated tape, which may be effective for heavy-duty packages and deterring thefts, and acrylic tape, which can withstand sunlight and air damage and stick well on dirty or dusty surfaces.
7. Underestimating the Importance of Labels and Instructions
Just as instructions for customers about the product itself are important, it is equally essential to include labels and handling instructions for shippers. These might specify that fragile or irregular products are inside and how shippers should handle these packages to avoid product damage. These messages need to be clear, complete and unambiguous. Some examples might include labels like “this side up,” “handle with care” and “fragile.”
8. Overlooking Cost Efficiency
When you don’t consider long-term costs when choosing a standard packaging solution, you may select one that is too expensive or cheap. This can lead to losses, as the packaging provides inadequate protection and requires you to spend more on extra cushioning materials. This makes it important to consider cost-effective custom materials and designs that can effectively reduce product damage and improve customer satisfaction.
You may also find a balance between cost and protection by thoroughly analyzing the expenses of ready-made packaging options, compared to an investment in custom solutions for irregular-shaped items. Custom solutions may be cost-effective because they optimize material use, reduce the likelihood of damaged product returns and lower the shipping volume.
9. Neglecting Sustainability
According to a McKinsey study, over 60% of consumers would pay more for a product with sustainable packaging. Neglecting sustainability may create a negative brand perspective.
You might also incur higher waste management costs when using nonrecyclable or nonbiodegradable materials that contribute to environmental waste. To reduce material usage, incorporate sustainable packaging practices like using recycled content, biodegradable materials, minimized packaging size, reduced filler materials or minimalist designs.
10. Inadequate Testing and Quality Control
Is your package sturdy enough to hold the weight and shape of your item? When packaging flaws are noticed too late or a company incorporates insufficient package testing — or skips the testing stage altogether — products may be damaged and possibly returned. Because irregular-shaped items can put pressure on certain points of a package, it’s important to perform a strength and durability test on packaging before full-scale production.
Some things you can do include shaking or moving the packaging around to check if the item remains well-protected and secure. You may enhance packaging effectiveness by partnering with a packaging company that uses extensive quality control measures like computer-aided design (CAD), a comprehensive development process and prototypes before mass production. This helps thoroughly evaluate all aspects of the packaging to ensure the item is more protected.
Use Protective Packaging Solutions From Great Northern Laminations®
To determine the best packaging for odd-shaped items, consider all aspects of the item, the shipping environment and related costs. Laminations is a protective packaging solutions manufacturer. We develop products that lower shipping and packaging material costs.
Our test lab allows us to test packaging performance during vibration, free-fall drops, material handling, inclines and compression. All of our paperboard materials are also recyclable, and our processes are eco-friendly. To learn more about our protective packaging for irregular items, contact one of our team members today.
