Oct 12, 2026
Prepare ecommerce packaging for peak season. Learn how right-sized corrugated packaging can improve fulfilment, reduce void fill and protect products.
Peak season demands do not create packaging problems; it exposes them. When ecommerce volumes rise, small packaging inefficiencies become much harder to ignore.
A pack that is too large, slow to assemble, awkward to select or poorly suited to the product may feel manageable during quieter periods. Under peak demand pressure, the same issue can affect packing speed, storage space, transport utilisation, damage rates and returns handling.
That matters because ecommerce remains a significant part of the retail mix. According to the Office for National Statistics, online spending values rose by 3.0% in the three months to July 2026 compared with the previous three months, and were 11.0% higher than the same period in 2025. The proportion of sales made online was 28.3% in July 2026.
As brands and fulfilment teams prepare for peak season, packaging should be treated as part of operational readiness, not a last-minute purchasing requirement.
During peak, speed and consistency matter. Packing teams are dealing with higher volumes, more mixed baskets and tighter delivery expectations. Any friction in the packaging process becomes more visible.
If pack formats are difficult to identify, slow to erect or poorly matched to the product range, the packing bench loses efficiency. If there are too many similar packaging options, selection becomes harder. If the wrong size is chosen, businesses can use more void fill, take up more space and create a weaker delivery experience.
Peak fulfilment is not only about having enough packaging in stock. It is about having the right range of packaging available, clearly specified and easy to use at speed.
Oversized ecommerce packaging affects more than presentation. Larger-than-needed packs take up more storage space, increase the need for void fill and reduce the number of parcels that can move through cages, pallets, vehicles and delivery networks.
Right-sizing does not necessarily mean choosing one smaller box. Depending on the product range, it may mean introducing more appropriate case sizes, rationalising existing formats or using adaptable solutions, such as telescopic formats, that can accommodate different product sizes while reducing unnecessary space.
This is particularly important in a parcel market already operating at scale. Ofcom reported that people in the UK sent and received a record 4.2 billion parcels in 2024/25, up 7% on the previous year. The same research found that 68% of parcel recipients had experienced a delivery issue in the previous six months.
Packaging cannot solve every delivery issue, but it can help reduce avoidable risk by improving fit, protection, handling and presentation.
Reducing pack size or material can be valuable, but only if product protection is maintained. Peak season is not the time to discover that a packaging format is under-specified. Higher parcel volumes, tighter timeframes and greater pressure on delivery networks can expose weaknesses in pack strength, product movement, closure performance and return suitability.
Returns add another layer of complexity.
Whistl reports that 71% of UK online shoppers return items at varying frequencies.
There appropriate, ecommerce packaging can therefore benefit from features that make a second return journey easier, such as straightforward opening, resealable closures or designs that remain structurally suitable for return transit. Testing and validation are therefore essential.
Packaging should be reviewed against real fulfilment conditions, not just theoretical requirements. When to review your ecommerce packaging range Peak demands are increasingly about sustained fulfilment performance across multiple weeks, not simply one short burst.
Brands should be asking whether their ecommerce packaging range is fit for peak season volumes, whether it supports efficient packing, whether it reduces unnecessary air and void fill, and whether it offers appropriate protection through delivery and returns.
At VPK Packaging, we help customers review existing ecommerce pack ranges, reduce unnecessary formats, improve packing efficiency and develop fit-for-purpose corrugated packaging around the product, fulfilment process and delivery journey.
Peak seasonal demands will always create pressure. Right sized packaging helps prevent that pressure becoming avoidable cost. To review your ecommerce packaging ahead of peak season, contact VPK Packaging.
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