Starting a business is hard enough without packaging sabotaging your success. After working with thousands of startups and growing brands, we've identified the most common—and costly—packaging mistakes that entrepreneurs make.
The good news? Every mistake is avoidable. Here's what to watch out for and how to do it right.
Mistake #1: Ordering Too Much, Too Soon
The Problem:
Excited founders order 5,000-10,000 boxes to "get a better price." Then:
- They want to rebrand in 6 months
- Product size changes after customer feedback
- They're stuck with unusable inventory
The Reality:
The "savings" from bulk ordering disappear when you need to trash thousands of boxes.
The Solution:
- Start with 100-250 boxes to test your design
- Validate with real customers before scaling
- Factor obsolescence risk into "per-unit savings" calculations
- Work with suppliers who offer low MOQs (like our 100-unit minimum)
Pro Tip: Plan for 3-6 months of inventory, not 12-18 months. Your brand will evolve.
Mistake #2: Choosing the Wrong Box Size
The Problem:
Boxes that don't fit your product properly lead to:
- Damaged products (too big, things shift)
- Cramped presentation (too small)
- Wasted shipping costs (dimensional weight pricing)
- Poor unboxing experience
The Cost:
Oversized packaging can add $2-5 per shipment in dimensional weight charges alone.
The Solution:
- 1Measure your product at its largest dimensions
- 2Add 0.5-1" on each side for cushioning
- 3Consider void fill requirements
- 4Get physical samples to test fit
- 5Choose sizes that work for your product range
Pro Tip: Many carriers charge by dimensional weight. Right-sizing packaging saves money on every shipment.
Mistake #3: Skipping the Sample Step
The Problem:
Approving packaging based on digital mockups leads to surprises:
- Colors look different in reality
- Materials feel wrong
- Finishes aren't what was expected
- Quality issues discovered too late
The Solution:
- ALWAYS request physical samples
- View samples in different lighting
- Test durability and assembly
- Get feedback from others before approving
- At Brisk, we offer FREE sample kits
Pro Tip: Share samples with 3-5 people before final approval. Fresh eyes catch issues you'll miss.
Mistake #4: Design Without Brand Strategy
The Problem:
"Let's just make it look nice" leads to:
- Generic packaging that doesn't stand out
- Disconnection from brand identity
- Frequent redesigns as brand evolves
- Inconsistency across product lines
The Solution:
Before designing packaging, define:
- Your brand colors (actual Pantone codes)
- Typography guidelines
- Brand personality adjectives
- Target customer preferences
- Competitive differentiation
Pro Tip: Create a simple brand guidelines document before starting packaging design. It saves countless revisions.
Mistake #5: Ignoring the Inside of the Box
The Problem:
Plain, blank box interiors:
- Miss a branding opportunity
- Feel cheap and forgotten
- Don't encourage social sharing
- Fail to create memorable moments
The Impact:
40% of customers share unboxing experiences. A blank interior is a blank social post.
The Solution:
- Add inside printing (even simple patterns)
- Include a thank you message
- Use branded tissue paper
- Create Instagram-worthy reveal moments
Pro Tip: Inside printing often costs only $0.10-0.20 per box but dramatically increases social sharing.
Mistake #6: Forgetting About Shipping Stress
The Problem:
Packaging that looks great on your desk but fails during shipping:
- Crushed corners from handling
- Water damage from weather
- Product damage from impact
- Torn or ripped boxes
The Reality:
Your package will be:
- Thrown (yes, really)
- Stacked under heavy boxes
- Left outside in weather
- Handled 10+ times before arrival
The Solution:
- Choose appropriate material weight (e-flute minimum for shipping)
- Consider burst and edge crush test ratings
- Add protective inserts for fragile items
- Test by shipping samples to yourself
- Use weather-resistant coatings for outdoor delivery risk
Pro Tip: Ship test packages to friends in different regions. Real-world testing reveals issues mockups never will.
Mistake #7: Overlooking Regulatory Requirements
The Problem:
Packaging that doesn't meet legal requirements for:
- Food contact (FDA regulations)
- Child safety (CPSC requirements)
- Shipping materials (DOT regulations)
- State-specific laws (California Prop 65, etc.)
The Consequences:
- Product recalls
- Legal liability
- Fines and penalties
- Market access restrictions
The Solution:
- Research requirements BEFORE designing
- Work with suppliers who understand compliance
- Document material certifications
- Include required labeling from the start
Industries with strict requirements:
- Food & Beverage: FDA food-safe materials
- Cannabis/CBD: Child-resistant packaging
- Cosmetics: Ingredient disclosures
- Toys: ASTM safety standards
Mistake #8: Choosing Cost Over Quality
The Problem:
Selecting the cheapest option leads to:
- Flimsy packaging that damages easily
- Poor print quality that looks unprofessional
- Materials that feel cheap to customers
- Higher damage/return rates
The Math:
If cheap packaging causes even 2% more returns:
- 1,000 orders × 2% = 20 extra returns
- At $10 per return cost = $200 lost
- That's more than the "savings" from cheap boxes
The Solution:
- Calculate total cost of ownership, not just unit cost
- Consider customer perception value
- Factor in return/damage rates
- Test before committing to large orders
Pro Tip: Mid-range packaging often delivers the best value. Ultra-premium isn't always necessary, but rock-bottom usually costs more in the long run.
Mistake #9: No Plan for Sustainability
The Problem:
Ignoring sustainability concerns:
- Alienates eco-conscious customers (61% of millennials)
- Creates PR risk if called out
- Misses cost-saving opportunities
- Fails to meet retailer requirements
The Solution:
- Choose recyclable materials when possible
- Consider FSC-certified paper
- Reduce unnecessary packaging
- Communicate your sustainability story
- Start somewhere—perfection isn't required
Easy sustainability wins:
- Soy-based inks (standard at Brisk)
- Recyclable materials
- Right-sized packaging (less waste)
- Clear recycling instructions
Mistake #10: Treating Packaging as an Afterthought
The Problem:
Leaving packaging to the last minute results in:
- Rush fees for fast turnaround
- Compromised design decisions
- Wrong choices made under pressure
- Higher costs overall
The Timeline Reality:
Good packaging takes 3-4 weeks:
- 1 week for design/revisions
- 1 week for sampling/approval
- 7-10 days for production
- Shipping time to you
The Solution:
- Start packaging planning when product is 70% done
- Build packaging timeline into launch plans
- Have backup suppliers identified
- Build in buffer for unexpected issues
Pro Tip: The best time to start packaging is earlier than you think. The second best time is now.
Bonus: The Validation Checklist
Before finalizing any packaging, run through this:
Function:
- [ ] Fits product properly
- [ ] Provides adequate protection
- [ ] Easy to open
- [ ] Easy to reclose/store (if applicable)
- [ ] Survives shipping stress
Form:
- [ ] Aligns with brand identity
- [ ] Appropriate for target customer
- [ ] Photo-worthy presentation
- [ ] Professional print quality
- [ ] Tactile experience matches brand
Compliance:
- [ ] Meets regulatory requirements
- [ ] Required labels included
- [ ] Materials appropriate for product type
- [ ] Documentation available
Business:
- [ ] Within budget at target quantity
- [ ] Minimum order quantity workable
- [ ] Supplier reliable and responsive
- [ ] Reorder process clear
Ready to Avoid These Mistakes?
Learning from others' mistakes is the smartest way to succeed. At Brisk Packaging, we guide startups and growing brands through every step:
- Free design consultation to align packaging with brand strategy
- Low 100-unit minimums so you can test before scaling
- Free sample kits to feel before you commit
- Fast 7-10 day turnaround when you're ready to move
- Expert guidance from teams who've helped 5,000+ brands
Don't let packaging mistakes derail your brand. Let's get it right the first time.
