How to Choose the Right Box Size for your products

sukritiairi
Dec 3, 2025
3 min read

Updated: Dec 19, 2025

Choosing the right box size is one of the most important decisions when shipping products. A box that is too large wastes money on packaging and shipping. A box that is too small can damage your products.

This guide explains how to measure your items correctly, select the ideal box dimensions, and avoid the most common mistakes businesses make when shipping.

Corrugated shipping box with a measuring tape demonstrating how to choose the correct box size.

Step 1 — Measure Your Product Correctly

To choose the correct box size, start by measuring your product’s:

Length (L) — the longest side
Width (W) — the shorter side
Height (H) — how tall the item is

Always measure using inches for accuracy.

Add Cushioning Space

After measuring the item, add ½ inch to 2 inches to all sides, depending on the fragility of the product.

Non-fragile items → +½ inch
Clothing, retail items → +1 inch
Fragile items → +1.5 to 2 inches

This ensures room for bubble wrap, kraft paper, or corrugated inserts.

Step 2 — Pick a Box Size That Fits Properly

A properly sized box should:

Hold the product snugly
Leave enough room for protection
Not collapse or bulge
Not have excessive empty space

Why Too Much Space Is a Problem

Extra space means:

Items shift during transit
Increased damage risk
Higher shipping cost due to dimensional weight
More filler material needed

Step 3 — Understand Standard Box Sizes

Most corrugated boxes come in standard sizes. Choosing standard sizes helps you save money and avoid special manufacturing costs.

Common categories include:

Small boxes (for cosmetics, small electronics, accessories)
Medium boxes (for office supplies, tools, retail products)
Large boxes (for bulky or lightweight items)
Extra-large or oversized boxes (for big, lightweight goods or pallet shipments)

Prairie Packaging offers custom sizing for products that don’t fit standard dimensions.

Table showing standard shipping box sizes, their dimensions, best uses, and recommended wall types for packaging. — Standard box sizes with recommended uses and wall types to help choose the right packaging.

Step 4 — Match Box Size to Product Weight

Choosing the right wall type is just as important as selecting the right size.

Single-wall boxes → lightweight/medium items
Double-wall boxes → heavy, fragile, or stacked shipments
Triple-wall boxes → industrial or extremely heavy items

Size and strength must match the product.

Step 5 — Consider Shipping Distance

For long-distance or cross-Canada shipments:

Choose a box with extra cushioning space
Use a double-wall for heavy or fragile products
Avoid overly tight box fits
Keep enough room for protection during vibration, stacking, and transport

Example of a Correct Box Selection

If your product is:

10” x 7” x 4” (L x W x H)
Fragile

Add 1.5” cushioning space:

New dimensions: 13” x 10” x 7”

The standard box closest to this is a:

13” x 10” x 7” single-wall or double-wall box, depending on weight.

Common Mistakes to Avoid

Choosing a box “that looks about right.”
Using oversized boxes (increases shipping cost)
Packing fragile items in single-wall boxes
Not adding space for padding
Boxes that bulge or deform after sealing

Need Help Choosing the Right Box Size?

If you're unsure which box size is right for your product, Prairie Packaging can help. Our team can recommend the correct dimensions based on weight, fragility, and shipping distance.