Shipping Materials and Accessories

In fulfillment, shipping materials are the invisible lever behind every successful delivery. Boxes, void fill, tapes, labels, and packing accessories determine whether goods arrive undamaged, whether the packing process runs quickly, and whether shipping costs stay under control. Anyone who orders materials ad hoc or keeps too many variants pays twice: once in material costs and again through slower packing times, returns, and carrier surcharges.

This guide gives you a structured overview of shipping materials and accessories in e-commerce fulfillment: which materials you need, how to reduce assortments sensibly, how to organize storage and procurement, and what to watch out for regarding sustainability and carrier requirements.

Why Shipping Material Is More Than a Box

Every shipped order touches multiple materials - often without the customer noticing consciously. For fulfillment operations, however, they are business-critical:

• Product protection - Void fill and suitable box sizes prevent transport damage
• Process efficiency - Standardized materials at the packing station speed up every order
• Cost control - Correct sizes reduce dimensional weight and shipping rates
• Brand impact - Printed boxes, inserts, and clean packaging shape the customer experience
• Compliance - Packaging law, dangerous goods requirements, and carrier rules define minimum standards

Shipping Material Categories at a Glance

Professional fulfillment distinguishes five material groups that work together at the packing station:

1. Outer Shipping Packaging

The outer shell carries the product and includes labels and handling notes:

• Folding cartons made of corrugated board in various sizes (FEFCO types)
• Mailing bags made of paper or plastic for flat goods
• Padded envelopes for small, sensitive items
• Special packaging for bulky goods, dangerous goods, or sensitive electronics

2. Void Fill and Cushioning Material

Void fill secures products in empty space and absorbs shocks:

• Bubble wrap and Kraft Paper for standard orders
• Foam inserts and molded fiber for premium or fragile goods
• Wood wool, paper cushioning, and recycled chips as sustainable alternatives

3. Closure and Security

Without reliable sealing, boxes open during transport:

• Packing tape (PP, PVC, paper) in different widths
• Stretch film for pallets and grouped packaging
• Security closures and tamper-evident tapes for valuable goods

4. Labels and Inserts

Information and process control run through labels and documents:

• Shipping labels (direct thermal, thermal transfer)
• Address and barcode labels for internal processes
• Delivery notes, return labels, and promotional inserts

5. Packing Accessories and Tools

Small tools that speed up and secure the packing process:

• Knives, dispensers, scales, and label dispensers
• Cable ties, corner and edge protection
• Moisture absorber packs and VCI packaging for sensitive products

Shipping Material Groups

Material Selection by Product Type

The right material combination depends on product weight, Product Fragility, and shipping volume. The following table shows common mappings in e-commerce:

Box Size Strategy Comparison

Boxes and Size Strategy

Boxes are the most used shipping material. The decisive factor is not the lowest unit price, but the right size per order:

Common strategies:

1. Standard box - One format for all items; simple, but often too large and expensive in shipping
2. 3-size system - Small, medium, large cover 80 to 90 percent of orders
3. SKU-specific packaging - Each SKU has a defined package; optimal at high volume per item
4. Automatic box selection - WMS or packing software suggests size based on volume

Corrugated Board and FEFCO Types

For e-commerce fulfillment, these box types are especially relevant:

• FEFCO 0201 - Standard folding carton, versatile and cost-effective
• FEFCO 0427 - Auto-lock box for high-speed packing lines
• FEFCO 0300 - Telescope packaging for varying heights

The choice of corrugation (E, B, or C flute) affects stability and packing height. For most online retailers, E flute is sufficient for light to medium-weight goods; B flute provides more shock absorption for heavier items.

Void Fill: Protection vs. Sustainability vs. Speed

Void fill prevents products from moving inside the box. At the same time, it affects packing speed, material costs, and sustainability performance:

Tape, Closure, and Security

Packing tape is an underestimated cost and quality factor. For continuous fulfillment operations, these basic rules apply:

• PP tape (polypropylene) - Standard for light to medium cartons, cost-effective
• PVC tape - Higher adhesive strength, better for heavy cartons and cold storage
• Paper tape - Sustainable alternative, ideal for recycled cartons without plastic coating
• Printed tape - Branding and tamper protection in one step

Closure checklist at the packing station:

• Box fully folded and edges straight
• At least one H-seal (top and bottom) for heavy shipments
• No tape over label or barcode
• For valuable goods: tamper-evident closure or security seal
• Stretch film only for pallets, not as a substitute for box closure

Labels and Inserts in the Packing Process

Shipping materials also include everything that carries information. Missing or misplaced labels lead to delivery delays and returns:

Mandatory labels per shipment:

1. Shipping label with full address and tracking number
2. Barcode for carrier scan (readable, not covered)
3. Optional: return label or return QR code
4. For international shipments: customs documents in a visible pouch or as attachment

Inserts by strategy:

• Delivery note (required or optional depending on marketplace)
• Return notice and withdrawal instructions
• Promotional insert, voucher, or product recommendation
• Warranty card or care instructions for relevant categories

Material Flow at the Packing Station

Storage and Inventory Management of Shipping Materials

Shipping materials need dedicated storage space - directly at the packing area, not in the back shelf zone. Poor storage causes bent boxes, sticking rolls, and search time:

Storage principles:

• FIFO - Consume older box batches first
• Within reach - Keep high-frequency material within arm's reach at the packing station
• Store dry - Moisture weakens corrugated board and adhesive strength
• Minimum stock levels - Define safety stock for peak seasons
• SKU mapping - Define which material is intended for which product group

Procurement and Cost Optimization

Shipping materials are usually sourced via wholesalers, packaging specialists, or directly from box manufacturers. For profitability, the key factors are:

Reduce costs without sacrificing quality:

1. Reduce box sizes to the actual product assortment
2. Use volume discounts by consolidating orders
3. Analyze dimensional weight and eliminate oversized boxes
4. Automate void fill (air cushion machine) from 80+ shipments/day
5. Reuse return packaging where legally and hygienically possible

Sustainability and Packaging Law

Shipping materials are increasingly subject to regulatory requirements. In the German market, VerpackG (licensing) and EPR (Extended Producer Responsibility) are especially relevant. Sustainable material choices also reduce CO2 footprint and meet customer expectations:

• Prefer recyclable mono-materials
• Avoid overpackaging - every unnecessary box costs money and brand image
• Check reusable and return packaging where return rates are high
• Ensure licensing via dual system or packaging license provider

Integration into the Packing Process

Shipping materials only deliver value when combined with a defined packing process. Packing instructions per SKU, an ergonomic packing station, and clearly assigned material locations are essential:

Optimized material workflow in 5 steps:

1. WMS or packing list shows recommended box size
2. Employee takes material from the defined compartment (color coding)
3. Product is packed, void fill is added based on standard quantity
4. Closure, weight check, and label print
5. Quality spot check for new SKUs or material changes

From Order to Ready Shipment

If errors occur during quality control, the process returns to box selection - material and packing instructions are reviewed again.

Checklist: Set Up Shipping Materials

Use this checklist when building or revising your material assortment:

Planning:

• Top 20 SKUs analyzed by shipping volume
• Average package weight and volume determined
• Carrier size and weight limits considered
• 3-size box system or SKU mapping defined

Procurement:

• Suppliers compared (price, lead time, minimum quantity)
• Safety stock calculated for peak season
• VerpackG licensing clarified

Packing station:

• Materials stored within reach at the packing station
• Packing instructions stored per SKU or product group
• Label printer and scale calibrated
• Training conducted for all packing staff

Monitoring:

• Evaluate material consumption monthly
• Track return rate due to transport damage
• Compare shipping costs per size class
• Perform spot checks of material quality when changing suppliers

Avoid Common Mistakes

Even experienced merchants make recurring mistakes with shipping materials:

• Too many box sizes - Warehouse chaos and slow decisions at the packing station
• Oversized standard box - Unnecessary dimensional weight and high shipping costs
• Cheap packing tape - Tears during transport, complaints, and rework
• No safety stock - Standstill in peak season due to material shortage
• Material without packing instructions - Everyone packs differently, quality varies

Material Optimization: Milestones Over 6 Months

Related Topics

• Packaging Fundamentals
• Packing Process and Quality
• Packing Station Workflow
• Sustainable Packaging
• Packing Stations and Workspaces

Last update: July 6, 2026