Empty space in e-commerce packaging

In e-commerce, shipping a product in a box that is too large often means transporting air at the expense of the company. A package can thus be billed up to six times heavier than the actual weight of the product. This phenomenon, known as empty space in packages, is a hidden cost for e-commerce businesses. Online shops often use oversized boxes due to limited standard packaging sizes, which are used for shipping various products such as electronic accessories, clothing, or spare parts. While this simplifies inventory management, it leads to increased material consumption, more padding, and unnecessary volume in transport vehicles.

Empty space as a logistics indicator

According to the "Empty Space Economy" report by DS Smith, 34% of e-commerce executives surveyed admit that their packages are at least twice the size of the product they contain. Monitoring the empty space in packages is essential as a logistics indicator. This can be calculated by comparing the internal volume of the box with the volume occupied by the packaged product. The goal is not to eliminate all empty space, as a package must protect its contents from transport shocks, but rather to find the right balance between protection, dimensions, material consumption, and shipping cost.

Volumetric weight and billing

Carriers use volumetric weight to calculate the price of a package, which reflects the space occupied by the shipment. When the volumetric weight exceeds the actual weight, it is used as the basis for billing. The most common formula uses a divisor of 5,000: Volumetric weight (kg) = length × width × height (cm) / 5,000. The divisor depends on the carrier, destination, and service chosen. Some carriers, such as UPS, DHL Express, and FedEx, apply volumetric weight, while others like Chronopost and Colissimo use it for certain air shipments. Mondial Relay and GLS do not apply it.

Impact of box size on shipping costs

For example, a product that actually weighs 1.2 kg can be shipped in two different boxes. A standard box with dimensions 40 × 30 × 30 cm would have a volumetric weight of 7.2 kg, while a custom box with dimensions 25 × 20 × 12 cm would have a volumetric weight of 1.2 kg. The standard box would be billed at 7.2 kg, while the custom box would be billed at 1.2 kg. This difference in weight can significantly impact logistics budgets when repeated across many daily orders.

Additional costs of oversized packaging

Oversized boxes also lead to additional costs such as padding materials, damage, and returns. Padding materials like kraft paper, bubble wrap, air cushions, or padding particles are used to fill unused space, but they increase the cost of each order. These materials also require storage and time to install, which can add up in a warehouse setting. A better-fitted box can reduce the need for excessive padding without compromising protection.

Risks of oversized boxes

Oversized boxes increase the risk of damage during handling, especially if the padding is insufficient or poorly positioned. Damaged packages may result in refunds, replacements, and customer complaints. A properly fitted box, combined with appropriate corrugated cardboard, can reduce these risks.

Customer perception and environmental impact

Oversized packaging can also affect customer experience and the company's eco-friendly image. Receiving a small product in a disproportionate box may give the impression of waste. Customers are also left with large volumes of cardboard and filling materials to dispose of. In a market where post-purchase experience contributes to customer loyalty, reducing unnecessary packaging can enhance the company's image and resource use.

Strategies to reduce packaging waste

To reduce shipping costs, e-commerce businesses can analyze their current packaging operations. Three actions can lay the foundation for a more effective packaging strategy: auditing the dimensions of products and packages, reviewing the range of available boxes, and adapting the box to the order. Custom boxes can be used to size each package according to the item or order while preserving necessary protection.

Custom box production for large-volume shippers

For companies that regularly ship large volumes, internal production of custom boxes can be an alternative to purchasing boxes in many formats. This is done using a machine that transforms corrugated cardboard into packaging dimensions for each shipment. This solution is worth considering for companies with an extended catalog, high daily shipment volumes, and significant costs related to transport, padding, or packaging storage.

EU regulation on packaging waste

The European regulation on packaging and packaging waste (PPWR, regulation (EU) 2025/40), applicable since August 12, 2026, sets a maximum empty space rate of 50% for grouped, transport, and e-commerce packaging from 2030. Therefore, companies are well advised to optimize their packaging now rather than approaching the deadline.