Boxes and Filling Material

Boxes and filling material form the backbone of every shipping package in fulfillment. They protect goods on the way to the customer, determine shipping costs through weight and dimensional weight, and shape the unboxing experience. Wrong box sizes increase material costs and return rates; insufficient filling material leads to transport damage and complaints.

This guide explains which types of boxes and filling materials are used in e-commerce fulfillment, how to find the right combination for your products, and which cost and sustainability aspects you should consider.

Why boxes and filling material are strategically important

Every shipped order goes through several stress phases: picking in the warehouse, sorting at the hub, transport in the delivery vehicle, automated conveyor systems, and manual handling during delivery. Box and filling material must absorb these stresses – without making the package unnecessarily heavy or bulky.

The strategic importance is reflected in four dimensions:

• Product protection – Avoid damage, reduce complaint costs
• Shipping costs – Directly influence dimensional weight and rate tiers
• Packing speed – Standardized cartons speed up the packing station
• Brand perception – Clean, well-fitting packaging strengthens customer trust

Types of boxes at a glance

In fulfillment, corrugated cardboard cartons dominate. Choosing the right variant depends on product weight, stackability, and mechanical stress.

Corrugated board and flutes

Corrugated board consists of one or more middle layers (flutes) between liner papers. The flute determines stability and thickness:

1. E-Flute (approx. 1.5 mm) – Thin, for lightweight products and display packaging
2. B-Flute (approx. 3 mm) – Standard for shipping boxes up to medium weight
3. C-Flute (approx. 4 mm) – Higher shock absorption, common for heavier items
4. BC double wall – Combination for bulky goods and high stacking load

Box shapes and systems

In addition to material strength, box shape influences the packing process:

• Folding boxes (FEFCO 0201) – Classic shipping carton, quick to set up
• Auto-bottom cartons – Pre-folded for packing lines and high volumes
• Book mailers – For flat shipments, low dimensional weight
• Corrugated shipping envelopes – For flat, non-fragile items
• Reusable boxes – With second adhesive closure for returns

Filling material: types and applications

Filling material prevents products from shifting inside the box and cushions impacts. The choice depends on fragility, shape, and packing speed.

Paper-based filling materials

Paper is recyclable, cost-effective, and sufficient for most standard products:

• Packing paper (rolled) – Universally applicable, manual or with paper cushioning machine
• Folded packing paper – Pre-made cushions, faster at the packing station
• Corrugated inserts – Dimensionally stable dividers and base pads
• Shredded paper fill chips – Inexpensive but dusty; rather for B2B or heavy goods

Plastic-based filling materials

Plastic offers high protection at low weight, but requires sustainability considerations:

• Bubble wrap – Excellent for delicate items, low weight
• Foam chips (styrofoam/EPP) – High cushioning, difficult to recycle
• Foam mats – Custom-made for recurring product shapes
• Stretch film – Secures products in the box without additional volume

Specialty filling materials

For special requirements, specialized materials are used:

1. Antistatic packaging – For electronics and sensitive components
2. Moisture-barrier bags – For textiles and hygroscopic goods
3. Thermal packaging – Insulating fill for temperature-sensitive products
4. Insert boxes and dividers – Custom-fit securing without loose fill

Finding the right combination

Box and filling material are not chosen in isolation, but as a system. The decision process follows a clear sequence.

Step 1: Product analysis

Capture for each SKU or product group:

1. Weight and dimensions (length × width × height)
2. Fragility (breakage risk, scratch-sensitive, liquid)
3. Surface properties (polished, textile, sharp edges)
4. Value and return rate due to transport damage

Step 2: Determine box size

The box should enclose the product with minimal empty space. Rule of thumb: 2–3 cm clearance per side for filling material. Boxes that are too large require more filling material, increase dimensional weight and shipping costs.

Step 3: Select filling material

Orient yourself based on fragility:

• Robust goods (tools, books) – Packing paper or corrugated insert is sufficient
• Standard e-commerce (clothing, household goods) – Packing paper or paper cushion
• Delicate goods (glass, electronics) – Bubble wrap, foam, or combination
• High-value goods – Custom solutions, antistatic, double-wall corrugated

Process flow: box and filling material selection

Step 4: Pack test and approval

Before a combination goes into production, conduct an ISTA-compliant drop test or a simplified internal drop test:

• Free fall from 80–100 cm onto a solid surface
• Simulation of stacking pressure (weight on box)
• Transport test with realistic fill in a delivery vehicle scenario

Box warehouse and procurement

Storing boxes and filling material affects warehouse space, capital tie-up, and packing speed.

Optimize box assortment

Instead of dozens of individual sizes, 5–8 standard boxes that cover 80–90% of all orders are recommended:

• 3–4 sizes for single orders (S, M, L, XL)
• 1–2 book mailers for flat shipments
• 1 specialty box for exceptions (bulky goods, multi-item)

Storage and handling

• Store boxes stacked flat, avoid moisture
• Keep fast-moving boxes within reach at the packing station
• Filling material in dispensers or roll holders for ergonomic work
• Define minimum stock levels and align with delivery times

Box assortment efficiency

Costs and profitability

Boxes and filling material typically account for 3–8% of fulfillment costs per order – with incorrect sizing, this can be significantly higher.

Cost drivers at a glance

1. Material costs – Box price per unit, filling material per meter or kilogram
2. Shipping costs – Dimensional weight due to oversized boxes
3. Labor time – Time-consuming filling with unsuitable box sizes
4. Complaints – Transport damage due to insufficient protection
5. Storage costs – Space for box and filling material warehouse

Savings potential

• Box optimization – Smallest suitable box instead of one-size-fits-all
• On-demand filling – Paper cushioning machine instead of pre-made cushions
• Volume discounts – Annual contracts with packaging suppliers
• Return boxes – Reusable shipping packaging for high return rates

Sustainability for boxes and filling material

Sustainable packaging starts with material choice. Recycled corrugated board with a high recycled paper content is standard; filling material made from mono-materials makes disposal easier for customers.

Important levers:

• Recycled corrugated board (PAP 20) instead of virgin fiber carton
• Paper instead of plastic where product protection allows
• Minimize empty space – less material per shipment
• Packaging Act compliance – Observe system participation and licenses

Detailed strategies can be found in the article on sustainable packaging.

Checklist: setting up boxes and filling material

Use this checklist for warehouse setup:

• Product portfolio classified by weight, size, and fragility
• 5–8 standard box sizes defined and procured
• Filling material defined per product group
• Packing instructions documented per SKU or product group
• Pack test for delicate items conducted and approved
• Box warehouse at packing station set up ergonomically
• Minimum stock levels and reorder points defined
• Shipping costs calculated with dimensional weight of standard boxes
• Sustainability requirements (recycling, Packaging Act) reviewed
• Packing station staff trained and packing quality monitored

Avoiding common mistakes

These mistakes occur particularly frequently in practice:

1. One-size-fits-all box for all products – Wastes material, increases shipping costs
2. Too little filling material – Transport damage and complaints
3. Too much filling material – Unnecessary costs and poor unboxing experience
4. Damp box storage – Corrugated board loses strength
5. No pack test before go-live – Damage discovered only in live operation
6. Wrong flute for product weight – Box breaks under load

FAQ: frequently asked questions about boxes and filling material

How many box sizes do I need at minimum?

For most online shops, 5–8 standard sizes are sufficient. Start with S, M, L and a book mailer, expand as needed.

Paper or bubble wrap – which is better?

Paper is cheaper and more sustainable; bubble wrap offers better protection for fragile goods. Product analysis decides.

How do I store boxes correctly?

Flat, dry, away from direct sunlight. Moisture weakens corrugated board and leads to breakage during transport.

Is a paper cushioning machine worth it?

From around 50–100 packages per day, the investment often pays off through lower material costs and faster packing times.

Do I need Packaging Act licenses for boxes?

Yes, as a distributor of packaging you are obliged to participate in a system. Details in the article on sustainable packaging (packaging law).

Related topics

• Shipping material and accessories
• Protection and product safety
• Sustainable packaging
• Packing station workflow
• Packing stations and workstations

Last updated: July 6, 2026