In the fast-moving world of e-commerce, your packaging is your frontline defense against returns, damage, and disappointed customers.

Whether you’re shipping skincare, electronics, or apparel the journey from your facility to someone’s doorstep is full of bumps, turns, and tosses. Every damaged product that gets returned is not just a headache, it’s lost revenue, diminished customer trust, and precious time spent chasing fixes.

At President Container Group, we understand that what’s inside the box only matters if it arrives the way it should. That’s why smart, durable, and tested packaging is a critical part of delivering a consistent, reliable brand experience. When customers receive their orders intact and on time, it builds trust and encourages repeat business. Fewer returns help reinforce your brand’s reputation and keep customers coming back.

Here’s what every shipping pro needs to know to keep their packaging, and reputation, intact.

Why E-Commerce Packaging is Different

E-commerce packaging today plays a far more demanding role than simply sitting on a pallet in a warehouse. It has to stand up to the entire last-mile journey—navigating fulfillment lines, conveyor belts, delivery trucks, and the final drop-off at a customer’s front door. Every step is a chance for damage, and every well-protected product is a chance to strengthen your customer’s trust.

This isn’t a delicate supply chain. Packages are tossed, stacked, dropped, and left outside in the rain, snow, or 95-degree heat.

And here’s the real kicker: unlike retail packaging, you only get one shot at a first impression. That box becomes the unboxing moment, the brand interaction, and the product protection—all in one.

4 Common Causes of Damage in E-Commerce Packaging

Industry data shows that return rates in e-commerce can hover between 20–30%, especially in categories like apparel, electronics, and home goods. Not all of those are due to damage, but many are. Here’s what typically goes wrong:

1. Incorrect Board Grade or Weak Material

Using the wrong board strength is like sending your product into battle with rubber armor. Flimsy packaging collapses under pressure, literally. E-commerce cartons often require high-performance single-wall options like E-flute, engineered for durability without added bulk.

2. Poor Fit = Product Shift

Too much space inside the box invites trouble. Products shift, slide, and slam into each other. Overpacking doesn’t help either, it just bulges, crushes, or adds waste. Sizing needs to be precise, especially for heavy or fragile items. At PCG, we offer custom inserts and bubble wrap solutions tailored to your product. Whether you’re shipping something heavy, fragile, or oddly shaped, we can help you secure it from the inside out—reducing damage and enhancing the unboxing experience.

3. Inconsistent Glue Lines

At PCG, we test glue lines rigorously on our Fosber corrugators because those tiny seams are what hold the corrugated carton together. If the adhesive’s off, either too dry or too wet, you’re looking at boxes that could fall apart mid-transit.

4. No Moisture or Tamper Resistance

A shipping label slapped on a naked kraft box isn’t enough. For outdoor delivery or sensitive items, moisture barriers, tape integrity, and security seals are must-haves.

Best Practices for Preventing Damage in Transit

Here’s how to go from reactive to proactive:

Choose the Right Strength

Choosing the right board strength matters. Our team helps match board grade to the weight and fragility of your product, whether that’s single-wall, double-wall, or specialty configurations.

Fit Like a Glove

Right-size your box for your product. Void fill like kraft paper, foam, or custom inserts should secure, not smother, the contents. And remember: too much room = impact zone.

Why Partnering with PCG Makes a Difference

At President Container Group, we know your packaging is a reflection of your brand. Damaged boxes and high return rates put your reputation at risk. That’s why we’re committed to delivering packaging that performs, every time.

As one of the largest independent corrugators in the U.S., we deliver quality, speed, and scale. You won’t hear excuses about equipment limitations, we’ve invested in automation, latest advanced machinery, and quality controls that help our customers sleep better at night. From recovery supervisors to floor techs, our team checks every line for performance, and we’re always improving. 

How to Get Packaging Right for Your E-Commerce Business

Partner with PCG to get packaging that’s engineered for performance, built to scale, and tailored to your brand. Our team is ready to help you reduce risk, streamline fulfillment, and deliver a better customer experience—one box at a time.

Ready to reduce returns and make packaging your competitive edge? Request a quote today.