As people order and ship at historic rates, lessons learned from Q4’s peak season Shipathon will help with fulfillment in 2021.
Shipping volumes continue to break records as e‑commerce demand grows year-round, not just during the traditional holiday peak. Parcel carriers are experiencing consistently high package volumes, prompting ongoing surcharges and capacity adjustments to manage the load.
High-volume periods are no longer occasional—they’re the new normal. Companies must refine fulfillment processes, control costs, and take extra steps to protect merchandise as packages face more handling, stress, and transit impacts. The key to staying ahead? Learning from past peak seasons and applying those lessons proactively.
Read on for the most important takeaways to optimize your shipping operations and keep packages safe, costs manageable, and customers happy—even when volume surges.
Be Proactive About Problem-Solving
High-volume shipping surges can expose weaknesses in even the most robust fulfillment operations. Analyze your damage rates, cost per delivery, and return data to understand where problems are occurring. Are your usual packaging materials holding up under heavier loads and more frequent handling? Could investing in automation or upgraded packaging reduce labor and replacement costs?
Address packaging and fulfillment issues before demand spikes. Use sales forecasts to estimate potential damage costs at higher volumes, and weigh those against the investment needed to prevent losses. Taking action early ensures smoother operations, protects your products, and improves profitability when peak shipping periods arrive.
Prepare for Worst Case Scenarios
High package volumes aren’t just a seasonal challenge—they’re increasingly the norm. More packages moving through carriers and sorting centers means a higher risk of damage, delays, and handling stress.
Plan ahead by:
- Expecting delays from busy delivery networks and building extra processing time into your workflow.
- Upgrading packaging to protect fragile, bulky, or high-value items during transit.
- Streamlining operations to get shipments out quickly and reduce time in transit.
Proactively preparing for these challenges helps ensure your products arrive intact and on time, protecting both your bottom line and your customer relationships.
Solutions for Every Type of Challenge
Protect Against Drops and Impact
High package volumes increase the risk of drops or mishandling during delivery. Cushions like HC Barrier, Renew, and Inspyre provide high-pressure shock absorption and long-lasting air retention. Their square-bubble design maximizes protective surface area, while sheets conform tightly to box interiors to prevent products from “bottoming out.” Many of these solutions are produced with 30% recycled content and can be manufactured at semi- or fully-automatic speeds on systems like the AirSpeed® Ascent.
Reduce Vibration and Disturbance During Sorting and Transport
Overflowing conveyor belts and trucks subject packages to constant movement. Extruded Polyethylene and Laminated Polyethylene Foam Planks brace products to prevent shifting, protect edges, and cushion fragile components. Density and weight can be customized for product fragility, and the non-abrasive surfaces prevent scratches—making them ideal for glass, electronics, or delicate items. They can also be produced in multiple colors for easy identification or branding.
Prevent Compression During Packing and Loading
With cargo planes and trucks operating at full capacity, packages face increased risk of crushing. Foam-in-place systems like the IntelliPack® SmartBagger™ create custom foam molds that conform perfectly to products, providing six-sided protection. This solution is ideal for heavy, bulky, or high-value items, and its automation capabilities also speed up packing while ensuring consistent protection.
Protect Your Platform Access
For sellers on e-commerce platforms like Amazon or Wayfair, high damage rates can put account access at risk. Choosing the right packaging for each product—whether it’s furniture or jewelry—helps maintain low damage rates, protects your brand reputation, and keeps your access to major marketplaces intact.
Reduce Weight and Dimensions to Avoid Surcharges
Carriers increasingly charge for oversized or overweight packages. Right-sizing your packaging and reducing weight shouldn’t just be a holiday-season tactic—it’s essential for year-round cost control and sustainability. Implementing these strategies now helps lower shipping costs and reduces environmental impact.
The e-commerce boom presents historic opportunities, but capitalizing on them requires precise, proactive packaging strategies. Solutions like those from Pregis IQ leverage over 50 years of expertise to reduce damage rates, optimize fulfillment processes, and keep your operations running smoothly.
Ready to Protect Your Shipments and Optimize Fulfillment?
Don’t wait for the next surge to expose weak spots. Explore tailored packaging solutions, streamline your processes, and reduce damage before it happens. Partner with Pregis IQ to safeguard your products, control costs, and keep customers happy—every season, every shipment. Learn more about our services here.
