Multiple items in one package: box size, void fill, and what to pack separately
,
by Verpakkingdeals.nl
6 min reading time
You pack an order with three or four items differently than a single product. You choose the box size, distribute the weight, and decide what to keep separate.
One product in a box is easy: find the right size and you're done. It gets trickier when someone orders four things at once – a bottle, a booklet, something textile, and a small box. Then the question isn't just which box fits, but also what can lie next to what, what will shift, and where the weight will end up. This is precisely where most damage claims in small webshops arise.
Below is a workflow you can follow for every combined order, without having to rethink it for each order.
Step 1: sort first, then choose a box
Lay the items side by side on a table and divide them into four groups:
Heavy and hard — bottles, cans, tools, devices with a battery.
Fragile — glass, ceramics, anything with a screen.
Liquid or greasy — oil, gel, cosmetics, anything with a cap.
Soft and absorbent — textiles, paper, cardboard boxes with print.
Rule of thumb: heavy at the bottom, fragile in the middle, soft as a buffer on the sides and top. Liquids never go loose with textiles or paper in the same space — that's the combination where one leaking cap makes an entire order unsellable.
Step 2: the box size is determined by the stacked arrangement, not the number of items
Many people choose the box based on the number of items. It's better to look at how the items stack when you arrange them as they will be in the box. Measure that stack and add space for filling on each side: count on approximately 3 to 5 cm all around for fragile contents and 1 to 2 cm if everything is unbreakable.
If the stack doesn't quite fit into a mailbox box, first check if one item can lie flatter before moving to a parcel box. Mailbox boxes are 28 mm high; staying below that often saves a tariff step. You can check your carrier's maximum dimensions for a mailbox package on their own site — PostNL, for example, publishes them on their customer service page about dimensions and weight. These standards change occasionally, so don't rely on an old printout at the packing table.
For smaller shipments, the A6 size (180 x 115 x 28 mm, bundle of 100, € 17.95) is useful to keep as a standard alongside. Three standard sizes are enough for most webshops; more sizes mainly mean more hesitation when packing.
Step 3: preventing shifting is more important than soft packaging
Damage rarely occurs because a box falls. It happens because items move against each other during transport — for hours on end, in a moving delivery van. So each item needs its own layer around it, and the remaining space in the box must be filled.
Fill the remaining cavities. Shake the closed box: if you hear anything moving, it's not ready.
For gift orders, a decorative filling like Pink Foam Hearts (± 77 pieces) (€ 4.99) can be both filling and presentation.
Step 4: what to keep separate inside the box
A box-in-a-box sounds cumbersome, but it's the cheapest insurance there is. Use internal packaging when:
There is liquid in the order. Place the bottle in a sealed bag or its own small box, so a leak doesn't reach the rest.
Something edible is included. Keep it separate from cosmetics, cleaning products, and anything with a strong odor; cardboard absorbs odors. A Mini Pizza Box 85x85x20 mm (100 pieces) (€ 10.00) is a cheap internal box for this.
There are sharp edges or loose parts. Anything that can scratch first goes into its own separate packaging.
Step 5: Taping and sealing
The heavier and fuller the box, the more important the closure. Tape the bottom in an H-shape: one strip over the seam and one over each short side. For a heavy box, double-tape the bottom.
Finally, always include a packing slip with a combined order. For a single item, the customer immediately knows what they have; for four items, a list is the difference between "complete" and an email where someone is missing something that was indeed in the box.
Two small boxes or one big box?
Sometimes splitting is cheaper or safer than combining: for example, if one item can fit flat through the letterbox and the rest will be sent as a package anyway, or if the combination of liquid and textile is too risky. Just calculate it once for your most common order combinations, and establish the outcome as a rule at the packing table. That saves daily deliberation.
Choosing a USB hub for working from home: 2.0 or 3.0, how many ports, and with switches
· 3 min reading time
Choosing a USB hub for working from home: 2.0 or 3.0, how many ports and with switchesYour desk needs three USB devices, but your laptop only has two ports. Or...
Power outages in autumn: emergency supplies you'll actually use
· 2 min reading time
Autumn Power Outages: Emergency Supplies You'll Actually Use October to December. Heating isn't in full swing yet, but the nights are getting long and cold. If a power outage strikes...
Choosing a power bank: capacity, charging speed, and weight compared
· 2 min reading time
Choosing a Power Bank: Capacity, Charging Speed, and Weight Compared Your phone dies when you're out and about. The classic emergency solution is a power bank. But what capacity do...
