Packaging Cost Calculator

Calculate total packaging cost per shipment and monthly spend with a visual breakdown.

Packaging Costs Per Shipment

Box / Mailer Cost ($)

Corrugated box or poly mailer

Poly Mailer Cost ($)

If using both box + mailer

Bubble Wrap / Dunnage ($)

Tape per Shipment ($)

Shipping Label ($)

Branded Tissue / Inserts ($)

Tissue paper, thank-you cards, etc.

Volume & AOV

Monthly Order Volume

Orders shipped per month

Average Order Value ($, optional)

Used to calculate % of AOV

Controlling Packaging Costs

Packaging typically represents 1–5% of revenue for most ecommerce businesses, though branded packaging can push this higher. Understanding your cost per shipment helps you make informed decisions about packaging quality vs. cost.

Right-size your boxes — using boxes that are too large wastes money on void fill, increases DIM weight charges, and uses more tape.
Buy in bulk — packaging costs drop significantly at higher volumes. Negotiate with suppliers at 500, 1,000, and 5,000+ unit thresholds.
Poly mailers vs. boxes — for non-fragile soft goods, poly mailers cost 60–80% less than boxes and weigh less, reducing shipping costs.
Branded packaging ROI — unboxing experiences can reduce returns and increase repeat purchase rates. Factor in the revenue impact, not just the cost.
Reduce inserts — digital alternatives (QR codes to a landing page) can replace printed inserts at near-zero cost.

Industry benchmark: packaging cost under 3% of AOV is considered efficient. Above 5% warrants a packaging audit.