Packaging Mistakes Hurt More Than You Think

Damaged products. High return rates. One-star reviews. 

Most of the time, these issues come down to one thing: packaging mistakes.

It’s not always obvious. Sometimes it’s the wrong box size. Other times, it’s a missed detail—like tape that fails in cold weather or foam that looks fine but can’t handle vibrations. Packaging mistakes cost more than money. They hurt your brand.

Let’s walk through the most common packaging mistakes we see (and a few packaging design tips to fix them).

1. Using the Wrong Materials

All boxes are not created equal, and creating a memorable unboxing experience takes careful consideration.

A standard brown box might work for some products, but that doesn’t mean it works for yours. Packaging needs to match what’s inside and how it’s shipped. The right material protects your product and helps avoid costly damage in transit.

Foam inserts, corrugated dividers, and temperature-resistant liners all exist for a reason. If you’re shipping electronics, high-end cosmetics, or perishables, take time to evaluate whether your packaging is truly doing its job to avoid shipping damage.

Recently, a new client came to us reporting a high breakage rate with their old packaging company. After investigating, the fix wasn’t just stronger packaging—it was smarter packaging that addressed both impact and vibration. After a redesign, damages dropped significantly which has made a huge impact for the brand.

2. Skipping the Fit Test

Oversized boxes waste material and raise your DIM weight. Undersized boxes apply too much pressure and lead to breakage. Neither one is good.

Products should sit snugly in their packaging, with just enough room for cushioning. A good test? Shake the box. If you can hear the product moving, rethink the layout.

Don’t forget to account for bundled items or sets. If your product is one of several in a shipment, design your packaging with dividers or interior supports that keep everything stable.

3. Overpackaging (or Underthinking Waste) is a Lesser-Known Packaging Mistake

More filler doesn’t always mean more protection.

In fact, too much padding can lead to confusion, mess, and frustration. Customers don’t want to dig through a pile of peanuts or unwrap three layers of bubble wrap.

Wasteful packaging also sends the wrong message. Brands like Allbirds and Lush are winning customers by cutting excess and going minimalist—without sacrificing protection.

Look for ways to use fewer materials and make disposal easier. Kraft wraps, molded pulp inserts, and recyclable tape are smart alternatives. You need to find a balance if you want to avoid shipping damage and keep your customers happy during the unboxing event. 

4. Hard-to-Open Designs

If your customer needs a box cutter, scissors, and patience just to open the box, something’s gone wrong.

Wrap rage is real. It shows up in reviews, refund requests, and social media posts. It’s one of the reasons that we’re seeing such a demand for minimalist packaging options. 

Ease of use is part of the customer experience. Design your packaging so that it opens without hassle. Tear strips, resealable closures, and intuitive folds all help.

5. Forgetting the Shipping Journey

Your packaging might look great in a warehouse. But what about in the back of a FedEx truck in February?

Packaging needs to be designed for the real world. That includes:

• Drops and vibration during sorting
  
• Exposure to heat, cold, or moisture
  
• Warehouse stacking and last-mile delivery
  

One of our client’s old packaging passed the visual test—but not the journey. It looked intact, but the doors were arriving broken. The issue was internal vibration and poor sizing, something that our protective packaging solutions fixed immediately. Once updated, customer complaints dropped significantly.

Map out the actual journey your package takes. Then test accordingly.

6. Weak Branding or Generic Design

Packaging is the first thing your customer sees. It’s the closest thing you have to a physical store window.

If it’s plain, generic, or forgettable, you’re missing a chance to make an impression.

The solution isn’t expensive custom printing. It’s intentional design. For many forward-thinking brands, the goal is to create tissue, stickers, and tape that match your identity on sustainable materials. 

Aim for custom packaging that allows you to compete with the big brands. Even a simple branded sticker can turn a mailer into something that feels personalized.

7. Ignoring Labeling and Print Errors

Misprints, typos, and misaligned labels look unprofessional—and they’re hard to fix once shipped.

Customers notice. And they judge.

Set up a clear proofing process. Check your packaging design with multiple eyes before it’s finalized. Read your copy aloud. Look at everything in real size, not just on a screen, and save your customer experience.

8. Not Testing For Packaging Mistakes

The simplest fix? Ship one to yourself.

Too many businesses don’t do this. They approve packaging in theory, not in practice. Send a few test orders to different addresses. Include varied climates, carriers, and shipping methods. This is important in all industries, and crucial for medical and pharma companies who rely on protective packaging. Businesses shipping electronics should also never skip this step, which would be a massive packaging mistake. 

Watch how it holds up. Then make changes.

Fixing Packaging Mistakes with Atlas

At Atlas Packaging, we’ve seen these problems. And we solve them every day.

We work with brands that care about their custom experience and want packaging that works in the real world—not just on paper. Whether you’re launching a new product or tired of damaged returns, we can help.

Our team takes the time to understand your product, your process, and your goals. We don’t push one-size-fits-all solutions. We design packaging that protects what you sell, reflects your brand, and fits your budget.

If you’re serious about reducing waste, cutting shipping and shipping damage costs, or improving customer satisfaction, it starts with better packaging. Let’s build something that works—and looks good doing it. Contact us today.