Skip to main content
Barton Jones Packaging Ltd
Industry solutions

E-commerce and returns packaging

Right-sized mailers and shippers that cut courier bands, speed up the pack bench and survive a return journey without a second box.

The problem

What usually goes wrong

Most online sellers use three box sizes for thirty products. Everything else gets filled with void fill, which costs money, slows the bench and pushes parcels into a higher courier band.

Oversized packs also look wasteful to customers, and the void fill is usually the first thing they complain about.

Returns are the part nobody specifies. If the pack cannot be re-closed, the customer improvises, the product comes back damaged, and you carry the loss twice.

Typical pack

Packaging components we usually specify

  • Die-cut postal boxes and e-commerce mailers sized to your top-selling lines
  • Peel-and-seal returns strips so the same pack goes back
  • Printed outers and printed tape carrying your brand
  • Paper void fill and Paperwave air cushions for plastic-free filling
  • Padded jiffy bags, document wallets, tubes and mailer bags for small items
  • Bubble wrap, bubble bags and foam for fragile lines

Materials

Relevant materials and board grades

  • E flute (approx. 1.5mm) for a smooth, sharp print face on retail-facing mailers
  • B and C flute single wall for everyday shipping boxes up to around 15kg
  • EB double wall where a premium unboxing needs strength and a clean face
  • Paper tapes, paper mailers and paper void fill for plastic-free despatch
  • Recycled and kraft liners, FSC certified under licence C214479

In-house

Our manufacturing and assembly capabilities

  • Bespoke die-cut sizes made in-house, with runs from as little as one and advice on the most cost efficient run rate
  • Printed boxes and printed tape so branding does not depend on stickers
  • Prototype and sample first, so you can weigh and measure before committing
  • Assembly and kitting where a pack ships with inserts, cards or accessories
  • Full despatch bench supply: tape, dispensers, void fill and mailing bags on the same order

Stock holding

How we hold stock for you

  • Buy a year of your best-selling sizes at volume price, call off monthly
  • We hold the pallets so your unit space stays available for stock
  • Free delivery on orders over £100 within 30 miles of Letchworth Garden City

Accreditations

Relevant accreditations for this sector

  • FSC C214479
  • BRCGS Storage & Distribution
  • Verified Carbon Standard
See our accreditations and request the literature

Real example

Three sizes to seven, and a courier band saved

An online retailer was shipping everything in three stock box sizes and filling the difference with loose fill. Their average parcel was around 30% larger than it needed to be.

We measured their top twenty SKUs, consolidated them into seven bespoke die-cut sizes and added a peel-and-seal returns strip.

Most parcels dropped a courier size band, void fill spend fell sharply, and pack time per order came down because there is nothing to stuff. Returns now come back in the original box.

Sector enquiry

Send us your top five SKUs

Give us the dimensions and weights of your five best sellers and your current box sizes. We will show you what right-sizing saves on carriage and void fill.

  • Product dimensions and weights
  • Current box sizes and monthly volumes
  • Courier and the size bands you pay
  • Whether you want a returns closure and printed branding
Use the enquiry form01462 680888

Related sectors

Other industry solutions