How To Prepare Small Items for Big Journeys
If you run an eCommerce business or you’re a sole trader shipping out orders from your garage, chances are you’ve had that moment of doubt right after dropping a parcel in the post: Will it make it there in one piece?
Small items, especially high-value ones, can be surprisingly vulnerable once they’re out of your hands. Whether you’re shipping jewellery, electronics, handmade goods or spare parts, long-haul transport routes come with their fair share of hazards. From damage to tampering and even theft, there’s a lot that can go wrong between point A and point B.
With the right packing solutions, you can dramatically reduce the risk of damage or loss, and save yourself the headache of replacements and unhappy customers.
Here’s how to prep your small items for big journeys.
Know Your Risks
First, let’s talk about what your parcels are actually up against.
Crushing
Items get stacked, dropped and jostled around during transport. Weak packaging will buckle under pressure.
Puncture
Conveyor belts, forklift tines, or even sharp objects in shared satchels can pierce flimsy materials.
Theft
Small, high-value goods like electronics and jewellery are prime targets if packaging looks tampered with or too tempting.
Mis-sorts
If labels aren’t clearly visible or the packaging is non-standard, your item could end up taking the scenic route.
Weather
Rain, humidity, or excessive heat can all affect certain materials. Cardboard weakens when wet. Some adhesives fail in hot trucks.
These aren’t just rare disasters, these are everyday realities in shipping networks. So, preparing for them isn’t overkill; it’s smart business.
Choose the Right Primary Pack
Start with your item’s first layer of defence; the primary pack. This is the packaging that’s in direct contact with the item.
Here’s a quick breakdown of your main options:
Rigid cardboard boxes
Best for fragile or high-value items. Boxes offer superior crush resistance and protection, especially when paired with internal padding. Plus, there’s always a range of sizes to suit your specific needs, from really small to much larger products.
Padded mailers (bubble or foam-lined)
Great for small, moderately durable items like books, clothing accessories, or boxed cosmetics. It’s lightweight, with decent cushioning. For flat but fragile items like documents, prints, certificates or thin electronics (e.g. SIM cards or USBs), consider rigid envelopes. They prevent bending and add a professional touch.
Small satchels
Water-resistant and tough, these satchels are an affordable and versatile option. Shipping costs are significantly reduced as the material is lightweight. It may not be ideal for anything fragile or high in value, unless used as an outer wrap.
If your item can be easily bent, cracked, or punctured, it deserves a box. If it’s worth a lot of money, consider double boxing or nesting inside protective packaging. Ultimately, more protection equals more peace of mind, especially if the products are headed interstate or overseas.
Stop the Rattle, Prevent the Crush
If it moves, it breaks. That’s the golden rule. Once you’ve got your item inside a suitable box or mailer, make sure it’s snug and secure.
Here’s how:
Wrapping
Use bubble wrap, foam sheets, or corrugated cardboard wraps around the item to absorb shock.
Inserts
Cardboard dividers or custom inserts keep products from shifting.
Mini void fill
Use shredded paper, air pillows, or crumpled paper to fill gaps. The goal is zero movement.
Shake test
Close the pack and give it a firm shake. If you hear rattling or shifting, you need more padding.
Avoid over-packing, too much internal pressure can cause seams to burst.
Tamper-Evident Measures
You want your customer to feel confident that their package hasn’t been interfered with. This is especially important for high-value goods or anything sensitive.
Try these:
Security tape
Tamper-proof tape leaves a visible residue or warning if peeled off.
Seals or stickers
Custom stickers with branding or ‘void if broken’ labels act as deterrents and build trust.
Labelled closures
A simple ‘Do not accept if seal is broken’ label adds a layer of accountability during delivery.
Not only do these add protection, but they also give your packaging a more professional, cared-for look.
Use Secondary Containment
Think of this as a safety net. Secondary containment is especially useful if you’re sending multiple small items, or if the item itself is already in retail packaging that can’t be crushed.
You can:
Bundle items together
Use shrink wrap, tape or inner bags to group small items so they don’t scatter or get separated.
Nest boxes
Place your smaller box inside a larger one with padding in between. This helps protect the contents and makes the parcel more tamper-resistant.
Use outer cartons
Particularly for international or interstate shipping. Couriers treat standard-size cartons more predictably than irregular or tiny parcels.
Avoid reusing boxes for valuable goods. Worn edges and compromised flaps equals higher risk.
Extra Tips for Aussie Sellers
Watch the climate
If you’re shipping across Australia, remember we’re dealing with tropical humidity up north and desert heat out west. Sensitive items (cosmetics, food, electronics) need insulation or heat shielding.
Size matters
Oversized parcels cost more, but undersized ones can disappear. Aim for parcels that are large enough to be noticed but still efficient to ship.
Use tracking
Always use tracking, so make sure your label is clearly printed, protected with a sleeve or tape, and placed flat on the largest side of the box.
Handle With Care
A little extra effort in packaging can go a long way when your products are on the move across suburbs, states or even continents. In today’s competitive online market, getting goods to customers safely is expected as part of your brand service, so it’s important to make lasting impressions and cultivate a reliable reputation.
Remember, proactive packaging preparation prevents poor performance.
