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Checklist: Here's how to tell if your packaging contains excess air.

July 28, 2026 in
Checklist: Here's how to tell if your packaging contains excess air.
Trygve Desmet


Are you shipping air without knowing it? 

Packing air costs money: for transportation, filler material, and storage. Yet it happens often—especially in e-commerce or at fulfillment companies with a changing product lineup. Use this checklist to find out if your packaging could be more efficient. 


1. Is there padding material in your box? 

Bubble wrap, air bags, paper plugs ... If you need them as standard, your box is probably too big. Custom packaging can make this unnecessary. 


2. Do you have multiple sizes of boxes in stock? 

With only one or two standard sizes, you often have to choose “the best fit.” That leads to half-empty boxes. With box-on-demand, you can choose the right size for each shipment. 


3. Do you get complaints about damaged products? 

A box that's too big causes items to shift and bump into each other. The risk of damage is greater when your products aren't packed snugly. 


4. Are there any air pockets in your returns? 

Return shipments also cost money—and sending air back is a double loss. Return-friendly boxes with resealable strips help, but the size also plays a role. 


5. Do you use a lot of padding during peak periods? 

During peak periods, you’re more likely to resort to standard packaging. Smart automation such as Limitless Packaging® makes custom packaging feasible even then. 


6. Do you often have to reorder because your formats are missing? 

Packaging on a roll—like that offered by Limitless Packaging®—prevents inventory issues. You produce exactly what you need, when you need it. No air, no waste.