How to Choose Packaging for Your Product
Australian Made PackagingShare
The right packaging is not simply the smallest box or the strongest material. It is a system that needs to contain the product, protect it through handling and fit the way your team stores, packs and dispatches orders.
Start with the product
Record the facts that affect the pack before comparing materials:
- finished dimensions and packed weight
- fragile areas, sharp edges or delicate surfaces
- parts that can move, leak or separate
- sensitivity to moisture, dust, light or temperature
- whether the item is food, dangerous goods or otherwise regulated
Measure the product as it will actually be packed, including caps, handles, accessories and any retail packaging.
Map the handling journey
A pack used for shelf storage has a different job from one moving through couriers, pallets or repeated warehouse handling. Note how the product will be picked, stacked, transported, opened and—if relevant—returned. Australia Post advises businesses to follow the packaging guidance relevant to what they send and notes that half-empty boxes can collapse while overfilled boxes may burst.
Choose the layers you need
Not every order needs every layer. A packaging system can include:
- product or primary packaging to contain the item
- surface or impact protection such as paper, foam, bubble wrap or edge protection
- an outer pack such as a carton or mailer
- sealing and identification such as tape, labels or document wallets
- load unitisation such as stretch wrap or strapping for palletised goods
Use only the layers that solve a real packing or handling requirement.
Check fit before adding more material
Good fit helps control movement and reduces the amount of filler needed. Allow enough space for cushioning where it is required, but avoid a large outer pack around a small item. Check that closures seal without strain and that labels sit on a clean, flat surface rather than across an edge or fold.
Treat special requirements separately
Food businesses must use packaging that is fit for its intended purpose, is unlikely to contaminate food and will not introduce contamination during packing. Temperature, storage, reuse and the use of recycled materials can all affect suitability. Dangerous, restricted or temperature-sensitive goods also need product- and carrier-specific checks.
Run a packing trial
Pack a representative item using the proposed method. Check movement, compression, corners, seals, labels and ease of opening. For repeat work, write down the chosen components and packing sequence so different team members produce the same result. Re-test when the product, carrier, pack size or packing process changes.
Information to bring when asking for help
- product dimensions, weight and photos
- current packaging and the problem you want to solve
- shipping or storage method
- required pack or carton quantities
- special surface, food-contact, temperature or handling requirements
- rough order quantity and timing, if known
Browse boxes and cartons, protective packaging, mailers and films and wrap, or send us the application details for practical selection help.