Packaging Types

The right packaging type determines whether goods arrive undamaged, shipping costs stay within budget, and the packing process runs efficiently. In fulfillment, it is not about a single "best" packaging solution, but about the right combination of primary, secondary and auxiliary materials for each product and shipping route.

This guide presents the most important packaging types in e-commerce, explains their areas of application, and shows how to make a systematic selection – whether in your own warehouse or with a fulfillment service provider.

Packaging Levels: Primary, Secondary and Tertiary

In the fulfillment context, three packaging levels are distinguished. Each level fulfills a different role in the transport and warehousing process.

Primary Packaging

Primary packaging sits directly on the product. It usually comes from the manufacturer and serves product protection, labeling, and often point-of-sale presentation. Examples:

• Product cartons and folding boxes
• Blister packs and trays
• Bottles, cans and tubes
• Textile bags or poly bags around individual items

In fulfillment, primary packaging is rarely changed. However, it must be sturdy enough to serve as inner packaging in the shipping carton – or be additionally protected.

Secondary Packaging

Secondary packaging is the actual shipping packaging. It surrounds the primary packaging and protects the product on its way to the customer:

• Corrugated cardboard cartons (folding boxes)
• Shipping envelopes and padded mailers
• Bubble mailers
• Shipping tubes for posters and prints

Secondary packaging carries the shipping label, determines volumetric weight, and shapes the customer's unboxing experience.

Tertiary Packaging

Tertiary packaging serves transport between warehouse, fulfillment center and retailer – not end-customer shipping:

• Euro pallets and mesh boxes
• Stretch wrap and strapping bands
• Large cartons and bulk packaging for B2B deliveries

For pure B2C retailers, tertiary packaging mainly plays a role in goods receipt and warehousing.

Packaging Levels at a Glance

The Most Important Shipping Packaging at a Glance

For daily e-commerce shipping, a few packaging types are used that cover the vast majority of all shipments.

Corrugated Cardboard Cartons

Cartons made of corrugated cardboard are the standard in e-commerce. They are sturdy, recyclable, and available in numerous sizes. Typical variants:

1. Folding boxes (FEFCO 0201) – The classic shipping carton with four flaps, in many sizes from XS to XL
2. Auto-bottom boxes – For packing machines and high volumes, fast closure without much tape
3. Book cartons – Flat formats for books, documents and flat products
4. Multi-wall corrugated cardboard – Double or triple wall for heavy or fragile goods

The choice of flute strength (E-flute, B-flute, EB-flute) depends on the weight and fragility of the goods. Lightweight textiles are sufficient with E-flute; electronics and glass benefit from sturdier B-flute or multi-wall corrugated cardboard.

Shipping Envelopes and Padded Mailers

For flat, non-fragile items, shipping envelopes are often the more economical alternative to cartons:

• Paper shipping envelopes – For documents, textiles and flat goods without padding
• Bubble mailers – Integrated bubble cushions, ideal for CDs, jewelry or small electronics
• Foam-padded mailers – Higher protection for delicate but lightweight products
• Plastic shipping envelopes (Co-Ex) – Water-resistant, for outdoor or moisture-sensitive goods

Shipping envelopes save packing time and material costs but have lower stack stability in sorting systems. Carrier limits for format and weight must be observed.

Shipping Tubes and Special Formats

Specialized packaging types are used for certain product groups:

• Shipping tubes – Posters, prints, plans, long tools
• Garment boxes – Textiles without creases, with hanger bar or fold
• Thermal packaging – Food with cool packs or insulation
• Dangerous goods packaging – Approved packaging per ADR/IMDG for lithium batteries, aerosols and chemicals

Void Fill and Cushioning Materials

Void fill closes empty spaces in the shipping carton and secures goods against movement. The choice affects protection, costs and sustainability.

Packaging Types by Product Category

The optimal packaging type depends heavily on the product range. This mapping helps with initial selection:

001. Textiles and Fashion

• Poly bags or paper bags as primary packaging
• Shipping envelope or small carton, depending on crease sensitivity
• For premium ranges: garment box or branded folding box

002. Electronics and Accessories

• Keep manufacturer cartons as primary packaging
• Bubble wrap or foam insert in the shipping carton
• Antistatic packaging for sensitive circuit boards

003. Cosmetics and Liquids

• Check primary packaging for seal integrity
• Additional sealing or bag for leakage risk
• Dangerous goods packaging for certain ingredients or aerosols

004. Books, Media and Paper Goods

• Book cartons or sturdy folding boxes
• No oversized carton – avoid pressure marks
• Moisture protection for outdoor products

005. Bulky Goods and Heavy Items

• Double-wall corrugated cardboard or special carton
• Palletizing for weights over 30 kg
• Wooden frame or edge protection for edge sensitivity

Packaging Type by Product Group

Selection Criteria for the Right Packaging Type

Before you decide on a packaging type, you should systematically check these seven criteria:

1. Product weight and size – Does the packaging fit carrier formats and weight classes?
2. Fragility – Does the goods need cushioning, or is sturdy primary packaging sufficient?
3. Shipping costs – What volumetric weight results from different carton sizes?
4. Packing time – How quickly can the packaging be processed at the packing station?
5. Returnability – Can the customer reuse the packaging for a return shipment?
6. Sustainability – Recyclability, amount of void fill, VerpackG obligations
7. Branding – Is custom printing or brand color desired and economical?

Packaging Types in the Packing Process

The packaging type directly influences the workflow at the packing station. A well-thought-out range reduces decision effort and errors:

• Keep standard sizes on hand – 5 to 8 carton sizes cover 80 to 90 percent of shipments
• Packing instructions per SKU – Store in the WMS or at the packing station which packaging applies to which item
• Material at the station – Store cartons, envelopes and void fill within reach of the packer
• Standardize closure – Uniform tape and closure method (H-tape seal) for all cartons

Packaging Selection at the Packing Station

Costs and Cost Efficiency

Packaging costs consist of material, labor time and shipping rates. Typical benchmarks in B2C e-commerce:

• Paper shipping envelope: 0.10 to 0.30 euros per piece
• Standard folding box: 0.30 to 1.50 euros depending on size and quantity
• Bubble mailer: 0.20 to 0.60 euros
• Void fill material: 0.05 to 0.40 euros per shipment
• Branded custom carton: 1.50 to 5.00 euros and more

The cheapest packaging type is not always the most economical. A damaged product causes replacement delivery, returns processing and reputational damage – often many times the savings on the carton.

Packaging Cost Breakdown

Sustainability in Packaging Selection

Sustainable packaging types are gaining importance in e-commerce. Customers expect recyclable materials and minimal packaging waste. At the same time, obligations under the German Packaging Act (VerpackG) apply in Germany.

Sustainable alternatives at a glance:

• Corrugated cardboard from recycled fibers instead of virgin fiber
• Paper cushioning instead of styrofoam void fill chips
• Shipping envelopes made from recycled paper
• Reusable shipping packaging for suitable product ranges and return rates

Sustainability and product protection are not mutually exclusive. A carton that is too small with too little cushioning leads to damage – and thus to double resource consumption through replacement deliveries.

Checklist: Define Packaging Type per SKU

Use this checklist when defining the appropriate packaging type for a new product or SKU:

• Product dimensions and weight documented
• Fragility assessed (breakable, pressure-sensitive, liquid)
• Primary packaging checked for transport durability
• Suitable secondary packaging selected (carton, envelope, special format)
• Void fill defined or right-sizing confirmed
• Carrier limits for format and weight checked
• Shipping costs calculated with volumetric weight
• Packing instruction stored in WMS or packing guide
• VerpackG licensing for system-participation materials clarified
• Test shipment carried out and goods checked for damage

Packaging Types with 3PL vs. In-House Warehouse

Whether you pack yourself or use a fulfillment service provider: packaging types differ in availability and customizability.

In your own warehouse, you purchase packaging material yourself, define the range, and can switch at any time. You bear storage costs and procurement effort but have full control.

With a 3PL provider, the partner supplies standard packaging – usually corrugated cardboard cartons in common sizes. Custom packaging, branding and special materials are often available for an additional fee and should be agreed in the SLA.

Related Topics

• Packaging Fundamentals
• Pick-Pack-Ship
• Packing Stations and Workplaces
• Order Picking and Picking
• Equipment and Technology in In-House Warehouse

Last updated: July 6, 2026