Cutting Returns with Better Holiday Packaging
Holiday returns cost retailers billions each year, with packaging failures being a major driver. Damaged goods, oversized boxes, and poor protection lead to dissatisfied customers and costly reverse logistics. For packaging buyers, engineering better holiday packaging is one of the most effective ways to reduce returns and protect profit margins.
Why Returns Spike During the Holidays
- High order volumes: More packages mean more opportunities for failure.
- Rushed fulfillment: Mistakes in packing increase product damage.
- Fragile products: Gifts like electronics and glassware need extra care.
- Customer expectations: Shoppers expect pristine deliveries for gifting.
Packaging Strategies to Reduce Returns
- Right-size design: Prevents product shifting and dimensional weight charges.
- Protective inserts: Foam, molded pulp, or corrugated dividers secure fragile items.
- Durability upgrades: Double-wall corrugated for heavy or bulk SKUs.
- Moisture resistance: Coatings or liners protect against winter weather.
Clear labeling: “This Side Up” and handling icons reduce rough handling.
The Role of Testing in Return Reduction
Packaging validation ensures boxes survive real-world conditions:
- Compression testing for stacked trailers.
- Drop testing for rushed warehouse handling.
- Vibration testing for long-haul shipping.
Testing reduces the risk of repeat failures that erode consumer trust.
Balancing Cost and Protection
Not all SKUs need the same level of packaging reinforcement. Buyers should prioritize:
- High-value and fragile products.
- SKUs with past return issues.
- Items that ship long distances or through multiple carriers.
Holiday Packaging Solutions with Brown Packaging
Brown Packaging helps brands reduce holiday returns through smarter packaging design and testing. From right-sizing to reinforced corrugated and protective inserts, our solutions protect products and profitability. Contact us to strengthen your holiday packaging program.
References
International Safe Transit Association (ISTA). (2022). Test Procedures for Packaged Products in Transit.
UPS. (2023). Peak Season Returns and Reverse Logistics Report. Retrieved from https://www.ups.com
Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.
POP display design must serve two masters — maximizing visual impact in-store while minimizing logistics costs. Engineering the right balance between display footprint, assembly complexity, and shipping volume is critical
Functional features like tear strips, windows, and hang tabs can enhance consumer experience and retail appeal—but they also introduce engineering challenges. Each modification affects structural strength, converting efficiency, and cost.
Phat Snax is redefining the snack aisle with a mission to make America’s snacks better for you — without killing the flavor. Their products, like the Devil’s Cake, are high
When choosing corrugated packaging, box style directly impacts cost, strength, speed of packing, and customer experience. Two of the most common options are the Regular Slotted Container (RSC) and the
By submitting your information, you agree to our terms and conditions and privacy policy.
Holiday e-commerce volumes push packaging to its limits. Trailers are overfilled, handling is rushed, and parcels endure more drops and vibration than usual. Without proper
Mailing tubes have long been a popular choice for shipping and storing various items, from posters and blueprints to documents and delicate artworks. While they
As the holiday season approaches, ecommerce businesses have a golden opportunity to stand out and create a memorable shopping experience for their customers. One way