Cardboard / Shipping Box – The Dominant Packaging Material in E-Commerce – and Its Hidden Costs
The cardboard is the dominant packaging unit in e-commerce and the express, courier, and parcel (ECP) segment. It serves two functions simultaneously: protecting the product during transport and serving as the shipping packaging to the end customer. In automated fulfillment centers, millions of these boxes pass through sorting systems, automated packing stations, and scanning systems every day. The process chain—from order picking to shipment preparation—is often fully automated. The non-standardized variety of box sizes leads to suboptimal volumetric utilization in shipping at many companies—a frequently underestimated opportunity for optimization that directly impacts shipping costs, warehouse space requirements, and CO₂ emissions. For logistics decision-makers, it is worthwhile to regularly analyze the cardboard box portfolio: Too many different box sizes increase complexity at the packing station and reduce the degree of automation.