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Packaging Checks to Make Before Order Volumes Surge
Black Friday Packaging: prepare for peak sales
Peak season can put pressure on parts of a business that seem perfectly manageable for most of the year. As order volumes increase, the packaging that normally moves through your warehouse without a second thought can suddenly become one of the things slowing everything down.
Black Friday falls on 27 November in 2026, followed closely by Cyber Monday on 30 November and the Christmas trading period. That gives businesses a useful window to look at their packaging now, while there is still time to make changes.
You do not need to overhaul everything. A few well-chosen checks can reveal where packaging stock, packing processes or product protection could cause problems once orders start coming in faster.
1. Check your fastest-moving packaging
Start with the packaging your team uses every day.
Look at your cardboard boxes, mailing bags, packing tape, labels, protective packaging and pallet wrap. Which products move fastest? Which ones have run low in the past? Are there any packaging lines that would stop despatch if you ran out?
Your own historic data is a useful starting point. Review previous order volumes, stockouts and delays rather than trying to predict peak demand down to the last order.
It is also worth allowing for changes in the business. If sales have grown, you’ve introduced new products or expect a particularly strong promotion, last year’s packaging usage may no longer give you a complete picture.
The aim is to identify the packaging that really matters to your operation and make sure it is available when you need it.
Preparing for peak season isn't just about ordering more packaging.
It's about ensuring the right products are available, deliveries arrive when needed and your packaging processes remain efficient as order volumes increase.
2. Look at the sizes of your boxes
The right box dimensions can make a noticeable difference to the packing process.
If a product is regularly being packed into a box that is much larger than necessary, your team may be spending additional time filling the empty space. That also means using more void fill and storing larger cartons than you might need.
On the other hand, making a box too small can create its own problems. Products may be difficult to pack, protection can become compromised and staff may need to use alternative packaging.
Look at the products that account for most of your orders and check whether the cardboard boxes being used are a sensible fit. You may find that consolidating a few formats or introducing a better-sized box makes the packing process easier.
3. Check how much protection your products actually need
Peak season is a bad time to discover that a product is regularly arriving damaged.
Look at products that are particularly vulnerable to impact, crushing or movement during transit. Is the current combination of box, bubble wrap, foam or paper protection doing what it needs to do?
There is a balance to find here. Removing protective packaging simply to reduce material use can create additional waste if products become damaged. Equally, adding large amounts of protective material to every order may mean you are using more packaging than necessary.
Watch a few orders being packed and look at where protection is actually needed. You may be able to improve the specification without changing the whole packaging operation.
4. Time your packing process
A packaging review should not only look at what goes into the parcel. Look at what happens around it.
How long does it take to assemble your most-used packaging boxes? How many pieces of tape are applied? Does your team have to cut, fold or modify boxes? Are packers choosing different packaging formats for the same product?
These small differences become more noticeable as volumes increase.
If a process takes an extra 20 seconds on an ordinary day, that may not seem important. Repeated across hundreds of orders, it becomes a considerable amount of packing time.
This is why it can be useful to watch your team packing a normal batch of orders before peak. The people doing the job every day are often the first to spot where packaging is making the process harder than it needs to be.
5. Check your consumables, not just your boxes
Boxes tend to get most of the attention when businesses prepare for peak. The smaller packaging products can be easier to overlook.
Check your packing tape, labels, void fill, mailing bags, stretch film and other consumables against expected usage.
Tape is a good example. If one parcel normally needs two strips and another requires four, the difference can become significant when order volumes rise. It may be worth understanding why before simply increasing your tape order.
The same applies to pallet wrap and stretch film used around outbound pallets. Make sure the materials supporting the wider despatch operation have been included in your peak planning.
A packaging plan is only useful if it covers everything your team needs to get an order out of the door.
6. Review what happens when something runs out
Even with careful planning, demand can change.
A product may sell faster than expected, a promotion may perform particularly well or one packaging line may be used more heavily than anticipated. It is worth knowing what happens if a critical packaging item starts running low.
Can your supplier replenish it quickly? Is there a suitable alternative? Do you have another cardboard box that could be used without affecting product protection or delivery requirements?
Springpack offers next working day delivery on stocked lines for orders placed before 3:30pm. That gives businesses a way to replenish stocked packaging quickly when requirements change.
For bespoke packaging, the solution is different. Stockholding and call-off agreements can allow Springpack to hold larger quantities of bespoke packaging and release it as required, helping businesses manage their supply without having to store the entire quantity themselves.
Knowing your options before there is a problem is much easier than trying to find an alternative when a packing line has already stopped.
7. Decide which packaging improvements can wait
Not every packaging issue needs to be solved before Black Friday.
Some changes are straightforward. You may be able to change a stock box, adjust your protective material or improve the way packaging is stored relatively quickly.
A new custom packaging design is different. Bespoke boxes, branded tape and mailing bags require more planning, so it is important to distinguish between changes that can realistically be made before peak and those that are better planned for the new year.
That does not mean ignoring the bigger improvements. Make a note of them and start the process now, even if the existing packaging needs to carry you through the busiest period.
Peak season itself can also give you useful information. If a box repeatedly causes delays or one format consumes far more material than expected, you have a clear starting point for your next packaging review.
What should you do if you find a packaging problem?
Start with the issue most likely to affect your operation.
If a core box is running low, check its stock and replenishment time. If packing is taking too long, look at the format and workflow. If products are receiving too much or too little protection, review the packaging specification.
You do not need to change everything at once.
A useful peak-season packaging plan should give you confidence that the essential materials are available, your team knows what to use and there is a sensible solution if demand moves beyond expectations.Â
How Springpack can help
Springpack can help businesses review their packaging before peak and identify where changes could make the biggest difference.
The free Packaging Review is a useful starting point if you are unsure whether your current packaging boxes, protective materials or packing processes are working as efficiently as they could.
For businesses using bespoke packaging, stockholding and call-off agreements can also help manage supply. Springpack stores agreed quantities of bespoke products and releases them as required, giving businesses access to their packaging without needing to hold the full stock themselves.
For everyday stocked lines, next working day delivery is available when orders are placed before 3:30pm.
Preparing for peak does not have to mean redesigning your entire packaging operation. Often, the most useful improvements start with a closer look at what is already happening.
Check your fastest-moving packaging, review your box sizes, look at product protection and watch how your team packs orders. Then make sure the less obvious consumables are covered and understand what you can do if demand increases faster than expected.
The earlier you identify those pressure points, the more options you have. And if a bigger packaging improvement needs more time, you can start planning it now rather than carrying the same problem into another peak season.
Frequently Asked Questions
How do I prepare packaging for peak season?
Review previous packaging usage, check stock levels, identify your fastest-moving lines and make sure you can replenish essential packaging when demand increases.
What packaging should I stock for peak season?
Focus on the packaging your operation cannot run without, including cardboard boxes, packing tape, mailing bags, protective materials, labels and pallet wrap.
How can packaging improve packing efficiency?
The right packaging can reduce unnecessary packing steps, make products easier to pack and reduce the amount of additional void fill or tape required.
Should I change my packaging before peak season?
If your current packaging is causing delays, excessive material use or product protection issues, it may be worth making a change. Simpler stock packaging changes can often be made more quickly than bespoke packaging changes.
How can I avoid running out of packaging during peak season?
Use previous demand to estimate requirements, identify your critical packaging lines and understand your supplier’s replenishment times. Keep an appropriate buffer for products that are particularly important to despatch.
If you are interested in Packaging, Springpack are experts in the field. Our team of Packaging Experts have all of the answers to your packaging questions. Why not get in touch with us today?