Corrugated boxes for e-commerce shippers

What gets packed, and how it travels

E-commerce boxes travel alone. Unlike a case on a pallet, a parcel is dropped, conveyed, sorted down chutes and stacked in mixed cages with heavier parcels. The box is the only protection the product has, and it is also what the customer opens first.

Census Bureau figures put e-commerce at 17.1 percent of US retail sales in the second quarter of 2026, $340.2 billion seasonally adjusted. Much of that leaves a warehouse in a corrugated RSC or a die-cut mailer.

Where the wrong box goes wrong

The two common mistakes are a box that is too big and a board chosen for stacking when the box will be thrown. Too big means void fill, crushed corners and a dimensional-weight bill for air. ECT tells you how a box stacks on a pallet; a Mullen 200# rating tells you how it takes a knock. A parcel needs the second as much as the first.

Setting up a box range

Start from your order data, not your product list. Most stores find that a few combinations of items make up most orders; size boxes for those first, then add one or two larger sizes for bigger baskets. Keep a mailer for flat goods such as apparel and books. Reorder on a cycle tied to your sales, and allow for the fourth-quarter surge, when parcel volumes rise and every supplier is stretched.

Returns are part of e-commerce, and a box that opens cleanly and can be resealed makes them easier for customers. Some sellers choose mailers with a second adhesive strip for returns. Others print simple return instructions inside the lid. Each detail is cut or printed on the die or press, so plan it before ordering.

Questions buyers ask

How many sizes should an online store stock?

Fewer than most do. Group products by the inside dimensions they need with an inch of protection, and many catalogues fit in a handful of sizes. We quote each one by the bundle.

Should I use 32 ECT or 200# test for parcels?

Both carry a 65 lb maximum. 200# test is rated by bursting strength, which suits rough parcel handling; 32 ECT is rated for stacking and usually costs less. Many shippers use 32 ECT and move to 200# only for heavy or fragile items.

Can boxes be printed?

Plain kraft is our default. Simple one-colour print, such as a logo or handling marks, can be quoted on a custom run; tell us in the notes.