Packing parcels is a daily task for many UK businesses, from e-commerce retailers to manufacturers and trade suppliers. While it can seem routine, the way parcels are prepared has a direct impact on delivery success, customer satisfaction and operational efficiency. Poor packing leads to damaged goods, returns and unnecessary costs, while a well-designed packing process supports speed, accuracy and brand reputation.
Efficient parcel packing starts with the right workstations, materials and processes working together.
Why correct parcel packing matters
Every parcel goes through multiple handling points before reaching its destination. During transport, packages are stacked, moved and sorted repeatedly. Proper packing protects goods from impact, vibration and compression while ensuring parcels remain secure and clearly labelled throughout the journey.
A consistent packing approach also helps businesses optimise logistics workflows, reduce material waste and maintain a professional standard across all outgoing shipments.
Key stages of secure parcel packing
A reliable packing process can be broken down into five essential stages:
- Choosing the correct packaging
- Protecting the product
- Filling empty space
- Closing and sealing the carton
- Labelling the shipment clearly
Each stage plays a role in ensuring goods arrive safely and efficiently.
Choosing the right packaging
Selecting the correct carton is the foundation of secure packing. Boxes should closely match the size and weight of the items being shipped to minimise movement and reduce the need for excess filler.
When choosing packaging, consider:
- Strength and durability: Cartons should retain their shape under pressure from other parcels during transit.
- Type of packaging: Specialist cartons are available for fragile, temperature-sensitive or irregular items.
- Correct dimensions: Heavier goods require thicker, stronger board, while oversized boxes increase courier costs and material use.
Using the right box size also helps reduce waste and keeps packing stations organised and efficient.
Protecting the contents inside the box
Even the strongest carton will not prevent damage if items are free to move inside it. Internal protection is essential, especially when shipping multiple products in one parcel.
Best practice includes:
- Securing each item individually using bubble wrap, kraft paper or stretch film
- Preventing contact between items to avoid impact damage
- Stabilising contents so they remain fixed during transport
Proper internal protection significantly reduces breakages and returns.
Filling empty space effectively
Empty space inside a carton allows goods to shift during transit, increasing the risk of damage. Void fill materials absorb shocks and keep products in place.
Common filling options include:
- Cardboard filler produced from recycled cartons
- Paper-based fill for lighter or smaller shipments
- Air-filled cushions and mats for lightweight protection
The goal is to eliminate movement without adding unnecessary weight or cost.
Sealing cartons for transport
Once packed, cartons must be sealed securely to protect against accidental opening, loss or tampering during transit.
Common sealing methods include:
- Packing tape: Fast, cost-effective and easy to apply across high-volume packing operations
- Stapling: Adds additional security for heavier cartons and discourages interference
Whichever method is used, seals should be consistent and strong enough to withstand handling throughout the delivery process.
Labelling shipments correctly
Clear labelling ensures parcels are routed correctly and handled appropriately. Every shipment must display a legible address label with full delivery details.
Additional labels such as “Fragile” or orientation markings can help reduce handling damage. Labels should always remain visible and must not be obscured by tape or packaging materials.
Types of parcel fillers used in packing operations
While small businesses may rely on bubble wrap or reused materials, higher-volume operations benefit from professional filler solutions that improve speed and consistency.
Cardboard fillers
Cardboard fillers are one of the most sustainable options available. Using machines that convert waste cardboard into protective filler allows businesses to reuse packaging already on site. This reduces waste disposal costs while creating a reliable supply of packing material.
Air-filled fillers
Air pillows and mats are lightweight and efficient. They take up minimal storage space before inflation and add very little weight to parcels. This makes them ideal for high-volume e-commerce operations where shipping costs are closely managed.
Paper fillers
Paper fillers provide good protection for small or lightweight items. However, they are less suitable for heavy or high-volume shipments, as they compress easily and can increase material costs.
Improving packing efficiency with the right equipment
Many businesses are now investing in dedicated packing tables and filler production machines to streamline their packing process. Well-designed packing stations improve ergonomics, reduce packing time and help staff maintain consistent standards.
Producing fillers in-house also removes reliance on external suppliers and ensures materials are always available when demand increases.
Packing solutions from SRS Sales & Service
SRS Sales & Service supports businesses looking to improve their packing and internal handling processes. Our range of filler machines and material handling solutions are designed to integrate seamlessly into packing tables and warehouse workflows.
By helping businesses produce their own packaging materials and optimise packing stations, we support faster dispatch, reduced waste and more efficient day-to-day operations.
Contact SRS Sales & Service to discuss packing solutions designed around your business needs.
