The wrong box size costs you twice. A box that is too big wastes paper, needs more filler and raises your courier charge. A box that is too small crushes the product or bursts at the seams. Here is a simple way to get the size right before you place an order.
Step 1: Measure the product, not the old box
Measure the length, width and height of the product as it will be packed, including any bag, sleeve or inner carton. Write the three numbers in millimetres.
Step 2: Add space for protection
As a rule of thumb, add about 10 to 15 mm on each side for sturdy, light products, and more for fragile items that need cushioning. This gives you the inside size of the box. Always order by inside size, because that is the space your product actually has.
A worked example
| Length | Width | Height | |
|---|---|---|---|
| Product | 200 mm | 150 mm | 80 mm |
| Allowance (about 10 mm per side) | +20 mm | +20 mm | +20 mm |
| Inside size to order | 220 mm | 170 mm | 100 mm |
Step 3: Match the ply to the weight
Size is only half the answer. A light product on a short trip can go in a 3-ply box. Heavier, fragile or long-distance products usually need 5-ply. See our guide to 3-ply vs 5-ply vs 7-ply corrugated boxes.
Common mistakes
- Measuring the outside of an old box and ordering the same size, which gives you less room than you think.
- Leaving no allowance, so the product presses against the walls and corners.
- Choosing one big box for several product sizes, which wastes paper and filler.
- Forgetting printing or inserts, which also take space.
Check your size with our calculator
Enter your box size in our box size calculator to see the flat sheet size and the approximate weight of the box.
Ready to order?
We make custom-size corrugated boxes at our Hyderabad plant. The minimum order is 1,000 pieces per size, with delivery in 7 working days from approval. Call 9059501177 or email sales@nextinpack.in with your size and quantity.
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