How Custom Box Sizes Can Reduce Your Shipping Costs
- Deepanshu Rathore
- Jul 7
- 2 min read
Updated: Sep 12
If you run a business that regularly ships products across India or internationally, you already know that shipping charges can quickly eat into your profit margins. But did you know that simply switching to custom-sized boxes can help you save a significant amount on shipping?
In this blog, we’ll explain how custom corrugated box sizes can reduce shipping costs, with easy examples in Indian units to help you understand better.
Why Box Size Matters
Most courier companies like Delhivery, Blue Dart, DTDC, and India Post calculate shipping costs based not only on the actual weight but also on something called the volumetric weight.
Volumetric Weight Formula (for domestic shipping):(Length × Breadth × Height in cm) ÷ 5000
If your parcel is large in size but light in weight (like a toy, pillow, or bottle), you'll be charged more because it occupies more space in the delivery vehicle.
Example: Standard Box vs Custom Box
Let’s say you’re shipping a small product — for example, a Bluetooth speaker — that fits perfectly in a 15 cm x 10 cm x 8 cm box. But you’re currently using a bigger 25 cm x 20 cm x 15 cm standard-size box.
Using the standard box:
Dimensions: 25 × 20 × 15 cm
Volume = 7,500 cm³
Volumetric weight = 7,500 ÷ 5000 = 1.5 kg
Let’s say your actual product weight is only 0.8 kg
🚚 You’ll be charged for 1.5 kg instead of 0.8 kg.
Using a custom-sized box:
Dimensions: 15 × 10 × 8 cm
Volume = 1,200 cm³
Volumetric weight = 1,200 ÷ 5000 = 0.24 kg
Now, you’ll be charged the higher of actual vs volumetric weight, which is 0.8 kg — but still much better than 1.5 kg!
Shipping Cost Comparison
If your courier charges ₹25 per kg:
Standard box: 1.5 kg × ₹25 = ₹37.50
Custom box: 0.8 kg × ₹25 = ₹20.00
✅ You save ₹17.50 per parcel!
If you ship 1,000 parcels a month, that's ₹17,500 saved every month, or ₹2.1 lakhs per year — just by switching to custom boxes!
More Ways Custom Boxes Save Money
1. Less Packaging Material
Smaller boxes need less filler like bubble wrap, thermocol, paper, or air pillows — which also costs money.
2. Reduced Product Damage
When your item fits snugly, there’s less movement inside the box, which means fewer returns due to breakage.
3. Lower Storage & Transport Costs
Smaller boxes take less space in your warehouse and delivery vehicle, helping reduce overall logistics costs.
4. Better Brand Image
Eco-friendly packaging with the right size shows that your brand cares about waste and sustainability — a bonus for modern consumers.
When Should You Use Custom-Sized Boxes?
You sell the same or similar-sized products regularly.
Your products are lightweight but being charged high shipping.
You're using excess fillers to keep the product from moving.
Final Thoughts
Custom-sized corrugated boxes may seem like a small change, but they can result in big savings. With a little planning, you can reduce your shipping bills, improve customer satisfaction, and even enhance your brand's image.
📦 In shipping, every centimeter counts. Go custom and save big!
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