Choosing the right size of box may not sound like an issue but could make all the difference to your business. Whether you sell products online, run a retail store or manage a warehouse, the size of your packaging can impact everything from the protection of your products to shipping costs.
Imagine sending a small product in a box twice its size. You’ll end up buying more cardboard, adding extra protective padding and possibly paying more for shipping. On the other hand, a box that’s too small can damage your product or make packing a struggle.
While putting your products away, measure them first.
What Does Box Sizes and Dimensions Mean?
Several people use the terms box size and box dimensions interchangeably. Although they’re both very closely related, they don’t mean the exact same thing.
Box size refers to these categories, such as small, medium, large or extra-large. Box dimensions refer to the exact dimensions you need to use to prepare or select the packaging.
Most packaging suppliers use three measurements: L, W and H.
Length Width Height (L W H)
Here’s a simple breakdown:
Length: The longest side of the opening of the box.
Width: The shorter side of the opening.
Height: Measurement of the distance from the bottom to the top.
For example, a box 200 150 100mm is 200 mm long, 150 mm wide and 100 mm high.
These measurements will help you determine how much space is available in the packaging and whether your product will fit.
Why Does the Right Box Size Matter?
Packaging is not just about how you use the product but how it is spaced. This can affect your business in many different ways.
Keep Your Products Protected
What business wants most is a damaged order. If there’s too much empty space in the box, the product can move around during shipping.
As you sort items out, choose the proper size box. Bubble wrap, cardboard sleeves or other protections can be added to the box as extra security.
Keep Delivery Costs Under Control
For businesses sending a lot of orders each day, shipping costs can quickly add up. Many courier companies in the UK take parcel weight into account when calculating delivery charges.
If you are using oversized boxes, you can increase the price of your deliveries by up to 15%. Choose the right size box for your requirements to help save space and make your deliveries run more efficiently.
Give Customers a Better Unboxing Experience
First impressions matter. When a customer opens a parcel, it looks more professional with neat and professionally wrapped packages.
Particularly important is packaging for businesses that sell cosmetics, gifts, clothing and other premium products. In the hands of a good packager, every purchase will be felt more special.
How to Measure a Packaging Box Correctly
You don’t need complicated tools or technical knowledge to measure boxes. Just a ruler and a tape measure are often all you need.
Here’s how to do it.
1. Measure the Length
Open the box and measure from the top of the box to the bottom.
2. Measure the Width
Measure the shorter side of the horizontal opening of the box. Be sure to use straight measuring tape.
3. Measure the Height
Measure vertically from the inside bottom panel to the top edge of the box.
4. Record Your Measurements
Write down length, width and height.
In custom packaging, millimetres can be used because the measurements of smaller differences in size are easier to distinguish.
For example, if your product measures 120 80 40mm, you will need to allow for extra space for protective wrapping or inserts before you decide on the interior box size.
Your product should fit with out moving around too much.
Internal vs External Box Dimensions: What’s the Difference?
It’s one of those important details that’s easy to overlook when ordering packaging.
Internal dimensions measure the usable space in the box. You can use this information to check whether your product will fit into the box, and whether there’s room for protection.
Diameters from outside, these are the dimensions of the box from outside. These dimensions can be useful when planning shipping, storing, or inspecting parcel specifications.
The cardboard will also have an effect on the dimensions. Especially double-wall corrugated boxes have more walls than single-wall boxes, so there is less room inside.
Check with your packaging supplier what size boxes they require before you place your order. This can save you from ordering boxes that won’t fit your products.
Common Box Sizes for Different Products
Different products need different packaging solutions. One item of jewelry, for example, doesn’t need to be as packed as an electronic device or a subscription box.
The table below provides some example dimensions for common product categories.
| Product Type | Example Dimensions | Suitable Packaging |
| Jewellery | 100 × 80 × 40mm | Small gift box |
| Cosmetics | 150 × 100 × 50mm | Folding carton |
| Candles | 100 × 100 × 150mm | Product box |
| Clothing | 300 × 250 × 50mm | Postal box |
| Subscription kits | 250 × 200 × 100mm | Mailer box |
| Gift sets | 250 × 200 × 100mm | Rigid box |
| Electronics | 300 × 200 × 150mm | Protective carton |
| Large products | 450 × 350 × 250mm | Corrugated box |
These are general examples rather than fixed packaging standards. Always measure your actual products before choosing a box.
Which Packaging Box Style Should You Choose?
After you’ve worked out the dimensions, consider the type of packaging that will best suit your product.
Corrugated Cardboard Boxes
When it comes to shipping, storing or just getting goods online in stores, corrugated boxes are a solid option. The layered construction of the boxes provides strength and helps protect the products during transit.
They come in several sizes and on different boards and are suitable for everything from small parcels to large shipments.
Custom Mailer Boxes
For online shops, clothing brands, and subscription businesses, mailer boxes are a great choice. They’re easy to put together, and the boxes look nice when your customers open their order.
Customizing also helps businesses avoid overpackaging.
Folding Carton Boxes
Cosmétiques, skincare products, food and retail items can be stored in folding cartons. They are lightweight, easy to store before assembly, and printed with your designs.
Luxury Rigid Boxes
If you sell expensive products, you may consider the rigid boxes used in jewellery, gift sets, accessories and other high-end products.
They have a strong construction and are more attractive, so the presentation is even more memorable.
Common Box Measurement Mistakes to Avoid
Even a small error in measuring can cause problems when ordering packaging in bulk. If you do make a mistake in measuring, it’s best to know first:
Measuring the outside and not the inside: Measure from the inside of the item when determining the product fit.
Forgetting protective materials: Allow extra space for bubble wrap, inserts and padding.
This is not to mention that the thickness of the cardboard material will affect the amount of space inside the box.
Mixing measurement units: You should use millimetres or inches for all of your measurements.
Selecting oversized packaging: Extra space can increase material use and delivery costs.
The easy task of confirming these measurements before you start production can prevent costly delays and loss of time for your business.
Find the Right Box Dimensions for Your Business
Every product has its own packaging needs, and finding a box that fits perfectly is easy. Measure your product accurately and consider the protection you need during shipping. Choose a box style that fits your business.
The Printed Packaging offers a variety of packaging options depending on the products, their size, presentation and branding needs. Whether you’re looking for custom product boxes, printed mailer boxes, corrugated shipping cartons or luxury packaging, measuring can help.
Remember, packaging is more than just putting a product inside a box. Good packaging is about protecting what’s inside, making sure there’s no waste, and making sure the customer gets their package in the best possible condition.