❌ The 10 Most Common Shipping Mistakes (and How to Avoid Them)

In the fast-paced world of shipping — whether you’re selling products online or mailing personal packages — mistakes can cost you time, money, and reputation. From poorly packed items to unreadable labels, avoidable errors are more common than you might think.

This guide breaks down the 10 most frequent shipping mistakes in 2025 — and how you can steer clear of them like a pro.

1. Using the Wrong Size Box

Too big, and your item shifts (and breaks). Too small, and it gets crushed or tears through.

How to avoid it:
Use boxes that allow at least 2 inches of padding around your item. Stock a variety of box sizes for flexibility.

2. Insufficient Padding or Void Fill

Many sellers skimp on padding — and it shows. Items arrive cracked, dented, or broken.

How to avoid it:
Use enough bubble wrap, air pillows, foam, or kraft paper to protect from shock. Fragile items need double-boxing.

3. Reusing Damaged Boxes

Used boxes can save money — but if they’re weakened or crushed, they may fail in transit.

How to avoid it:
Only reuse boxes that are clean, undamaged, and strong. Reinforce all seams with quality tape.

4. Incorrect or Incomplete Labels

This is one of the most common — and most preventable — errors.

How to avoid it:

• Verify addresses using a shipping platform

• Include the correct ZIP code and apartment/suite numbers

• Never tape over barcodes

• Place labels on the flattest, most visible part of the package

5. Not Including a Return Address

If your label gets damaged or delivery fails, the carrier needs a return address.

How to avoid it:
Place a return address on the upper left corner (or back). Bonus: brand it with a logo sticker.

6. Using Cheap or Weak Tape

Low-grade tape breaks easily and can pop open under pressure.

How to avoid it:
Use strong, 2+ inch packing tape (not masking, duct, or Scotch tape). Reinforce seams with an “H” seal pattern.

7. Forgetting an Internal Packing Slip

If the box gets damaged or opened, the internal slip helps identify the shipment.

How to avoid it:
Include a simple invoice or packing list inside every box with the sender and recipient details.

8. Overlooking Weight and Dimension Accuracy

Guessing your package weight = unexpected charges, especially with USPS and FedEx.

How to avoid it:
Invest in a digital postal scale. Measure and weigh every package before purchasing postage.

9. Ignoring Carrier-Specific Rules

Each shipping service has guidelines for packaging, labeling, and restricted items.

How to avoid it:
Read carrier guidelines — especially for:

• International shipping

• Lithium batteries or liquids

• Package size limits

10. Not Offering Tracking or Proof of Shipment

If a package goes missing and you can’t prove shipment, you may eat the loss.

How to avoid it:
Always ship with tracking and proof of delivery, especially for valuable or time-sensitive items.

📦 Final Thoughts

Every shipping mistake teaches a lesson — but with this list, you can skip the trial-and-error phase. Whether you’re a seasoned seller or just getting started, avoiding these pitfalls leads to happier customers, fewer returns, and more efficient fulfillment.

Remember: good shipping is good business.