Choosing board strength by guesswork
Grabbing a stronger box "just in case" feels safe, but it drives up cost across every shipment without necessarily solving the actual problem. Board strength should match the weight, stacking, and handling conditions your product actually faces. See our Corrugated Board Grades guide before defaulting to the biggest number on the sheet.
Skipping cushioning on irregular shapes
A snug fitting box is not the same as a protected product. Odd shapes and delicate components need dunnage that actually conforms to them, not just a box that is the right outer size. Foam type matters here too. See Polyurethane vs Polyethylene Foam to match cushioning to the product.
Assuming standard corrugated covers a Mil-spec job
If a government or military contract calls out ASTM D5118 or a similar spec, standard commercial corrugated will not satisfy it, even if it looks similar on paper. Mil-spec board is chemically treated and QPL traceable for a reason. Confirm the required grade before production starts.
Overbuilding with a wood crate when a lighter option would work
Full wood crates are the right call for the heaviest loads, but they are often used out of habit rather than necessity. For mid weight shipments, ECorrCrate offers similar protection at a lighter weight and lower freight cost. See Wood Crate vs ECorrCrate to check which one your load actually needs.
Not accounting for the full shipping environment
A box that performs fine in a short, controlled shipment can fail in long transit, outdoor storage, or high humidity conditions. Distance, storage time, and handling points all affect the right material choice, not just the product itself.
Designing packaging after the product, not with it
The most expensive mistakes usually trace back to packaging being an afterthought. Bringing packaging into the conversation early, alongside product design, tends to catch problems before they turn into damaged shipments or last minute redesigns.
Getting it right the first time
Every one of these mistakes is avoidable with the right information up front. If you are not sure your current packaging is doing its job, that is worth a second look before the next shipment goes out.