How to Measure Your Product for the Perfect Box: A Step-by-Step Guide to Avoiding Sizing Errors

We all have gone through this phase, wether. you want to order a little tube of lipstick or USB drive, and within three days, a package is delivered to your house. It's the size of a microwave. You rip it open, searching all through a mountain of bubble wrap and packing peanuts, then you finally come across this little object at the bottom.

As a customer, all this is irritating and unproductive. However, that unoccupied space is a silent killer of profits as a business proprietor.

One of the best milestones a brand can achieve is ordering custom packaging, which can become stressful when the math is not done correctly. The box is very small, which makes your investment useless as your product cannot fit in it. An oversized box destroys your product on the way and increases your shipping prices tremendously due to the weight.

The technical magic of a professional, secure, and cost-effective unboxing process is operationalized through a single skill, i.e., precise measurement.

No error in sizing is not witnessed at Polo Packaging, and it can be prevented most of the time. You are selling candles, clothes, or electronics; either way, this guide will take you through the whole process of how exactly you should measure your product in order to have a perfect fit every time.

Step 1: Understand the Golden Rule (Inside vs. Outside)

There is one major point that you should possess before you can even grasp a ruler, and this is that dimensions are not universal.

When a packaging industry is used, when you observe a size in it (such as 6 x 4 x 2), you should know whether these are the Internal Dimensions or External Dimensions.

Internal Dimensions: Space within the box that can be used. This is the merchandise that makes your product fit.

External Dimensions: The exterior box size in terms of the size of the outer walls. This is what counts in shipping carriers and postage expenses.

Why does this matter? Due to the thickness of the materials. When you request a corrugated mailer box, the walls of the cardboard may be 1/8th of an inch (E-flute) or even more. When you purchase a box with an outer size of 6 inches and the size of your product is that of 6 inches, it will not fit. The walls take up space.

Pro Tip: At Polo Packaging, and most custom manufacturers, we work with Internal Dimensions. 

Step 2: Arranging Your "Product Tetris"

This is not difficult when you are shipping one square item. But most of the brands deliver several items, or those of a strange shape.

You need to make sure you set your product(s) on a flat table before you take measurements, and in the manner in which you wish your customer to find them when they crack the box.

• Are they lying flat side-by-side?
• Are they stacked on top of each other?
• One you using filler (crinkle paper, tissue, or custom inserts)?

In case you intend to utilize either bubble wrap or crinkle paper, wrap your item today and then take measurements. That padding adds bulk. When you take a measurement of the naked product and repackage it later, your box will be too tight.

Step 3: Measuring Length, Width, and Depth

Take a ruler or a measuring rod. You should locate three figures: Length (L), Width (W), and Depth (D).

The packaging world is such that the order does count. Almost invariably, it is expressed as L x W x D.

Length: This is normally the longer side of the opening. The length of the mailer box that you are looking at is the side that is going from right to left when facing the opening.

Width: This is the shorter side of the opening, and it runs front to back.

Depth: This refers to the vertical dimension, that is, how high the box is from top to bottom.

Measure the length, width, tallest dimensions of your pile of products. Be straight with figures - do not squeeze the product to shrink the figure.

Step 4: The "Wiggle Room" Factor

Suppose you have a candle jar which is precisely 3 inches wide, and you order a box which is also 3 inches wide, you are going to get into trouble. It will be friction-fitting--that is to say, your customer will have to force the product with his fingers.

You have to include an allowance or commonly referred to as wiggle room.

To obtain a standard snug fit and still have your product easily removed, we would make all sizes of your product 0.125 inches (1/8th inch) larger across.

• Product Size: 6" x 4" x 2"
• Ideal Box Size: 6.125" x 4.125" x 2.125"

When you are putting in a lot of loose filler (wood wool or tissue paper, etc.), you may wish to add an extra little more, especially to the depth in particular, so you do not squeeze the delicate paper when closing the lid.

Step 5: Why "Close Enough" Isn't Good Enough (DIM Weight)

It is tempting to think that, with a small product, a stock 10x10x10 box, and order it, though you expect your product to be small. Better safe than sorry, right?"

Wrong. This is where you lose money.

A pricing model, which is used by shipping carriers such as FedEx, UPS, and USPS, is known as a Dimensional (DIM) Weight. They do not simply weigh your package; they estimate the space that it occupies in their truck.

When you send a feather in a huge box, it is not the weight of the feather that is charged; it is the size of the huge box. Not only do you save money on the cardboard material by making the size of your box as small as safely possible. But every single shipping label that you print causes you to save money, as well. Saving thousands of dollars in postage in the first year by shaving an inch off your box height.

Step 6: The Mock-Up Test

 Test before ordering 500/1,000 custom boxes. And this does not require any fancy equipment.

You will need a scrap piece of cardboard (another Amazon box would be a great option), a ruler, and an X-Acto knife. Trace the size that you believe you will need, trace the edges, and fold it into a shape.

Put your product inside.

Is the lid easily and smoothly closing?

When you shake the product, does it shake back? (Rattles, fierce, must have more stuff to fill up, or a smaller box).

Does it look presentable?

Conclusion: 

The measurement seems to be technical; nevertheless, it is the basis of great packaging. Professionally-fitted box secures your product, reduces your shipping fees, and appears to be very professional.

You do not need to guess in case you are not certain. At Polo Packaging, we would be delighted to assist you in settling on the ideal size. You can even send us a sample of your product, and our structural engineers will make a measurement of it, consider the thickness of the material used, and will prefer to design a dieline that will fit your item like it was a glove