Author: Jason Martin
Reviewed by: Supply Chain Solutions Lead
Last updated: October 6, 2025
Executive TLDR
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Most damage comes from bad packaging choices, look-alike SKU swaps, and loose processes at receiving or pack.
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Fix it with a simple packaging matrix, scan at pick and pack, and clear ASN data that speeds dock to stock.
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Right size mailers and cartons to cut DIM weight and breakage, then rate shop every label.
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For supplements and cosmetics, capture lot and expiry and pick FEFO to avoid write-offs.
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Stand up a fast recovery loop, photo proof, relabel or rebag lane, and a clean returns process.
Want a damage-reduction plan you can deploy this month — Contact Product Fulfillment Solutions
Table of contents
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Why damage happens
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The prevention checklist
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Pack right without killing margin
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Special handling for dated and regulated goods
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Fast recovery when damage occurs
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Metrics that actually move the needle
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Why Product Fulfillment Solutions
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FAQ
Why damage happens
Damage is rarely random. It comes from oversized boxes, thin mailers, missing dunnage, look-alike SKU swaps, poor palletization, and messy receiving that hides defects. Tighten the inputs and the floor gets quiet. Start with clear data, clean locations, and a pack matrix your team can follow without guessing.
The prevention checklist
1) Clean receiving with ASNs
Book dock times and send a complete ASN. Match carton contents at the door, then hit a 1 to 3 day dock to stock target. If you need overflow or staging space, tap warehousing and storage solutions.
2) Barcode discipline and slotting
One scannable code per sellable unit. Separate look-alike SKUs and print large, high-contrast bin IDs. This pairs well with 3PL fulfillment.
3) Scan at pick and at pack
A second scan at pack stops swaps for small electronics, cosmetics, and accessories. Keep a tiny exception lane beside pack so relabel or rebag does not block the main line. See pick and pack services.
4) Lock a packaging matrix
Post which mailer or carton to use by product family. Include dunnage type and amount. Train once, then audit daily.
5) Carrier mix and label timing
Rate shop by weight, zone, and promise date. Print labels after the final scan to avoid waste. Protect margin with discounted shipping rates.
6) Data where people can see it
Keep dimensions, weights, hazard flags, and pack rules visible in real-time information so pickers and packers trust the instructions.
Pack right without killing margin
Right-sized packaging reduces breakage and DIM charges. Keep it simple.
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Mailers vs cartons: Use padded mailers for durable, compact items. Cartons for multi-piece or fragile items.
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Layering rules: Top, side, and corner protection for anything rigid or edged.
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Void fill: One rule per family so staff does not overstuff or underfill.
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Tape and seals: Standardize tape width and pattern.
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Cartonization matrix: A short table the team memorizes beats a novel no one reads.
As catalog complexity grows, bake the rules into ecommerce fulfillment services so systems suggest the right pack on order drop.
Special handling for dated and regulated goods
If you sell supplements, vitamins, cosmetics, or OTC:
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Lot and expiry capture at receiving and FEFO at pick keep freshness and compliance.
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Use location flags where lot picking is required.
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For sets and subscriptions, include component lots on build sheets with kitting assembly services.
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Document quarantine and destruction rules so returns do not leak back into sellable stock.
For category depth, review health and wellness fulfillment services.
Fast recovery when damage occurs
You will never hit zero. The win is quick, consistent recovery.
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Photo proof at open: Snap the outer and inner on any damage-flagged return.
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Triage lane near pack: Rebag, relabel, or rebox without blocking the main line.
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Simple claim kits: Store carrier forms, photos, and weights together.
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Customer-first response: Offer replacement or refund immediately, then chase the claim.
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Feedback loop: Adjust the pack matrix based on repeated issues and seasonality.
Keep the loop visible in real-time information so operations and support work from the same facts.
Metrics that actually move the needle
Track a few numbers and act daily.
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Damage rate per 1,000 orders by family
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Look-alike mispick rate and which SKUs cause it
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Billable weight vs actual weight after pack changes
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Dock to stock time and ASN mismatch counts
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Cost per order before and after packaging changes
Report these weekly. Fix the biggest outliers, then retest.
Why Product Fulfillment Solutions
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Central U.S. hub in Cincinnati to reach most customers in 1 to 3 days by ground.
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Barcode-first receiving aligned to your ASN for predictable dock-to-stock speed.
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FEFO and lot or expiry control tailored for supplements, vitamins, and cosmetics.
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Pack standards with scan at pack, exception lanes, and right-size packaging.
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Small-parcel optimization that rate shops every label and trims DIM.
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Retail and marketplace readiness with simple label templates and EDI solutions and connections.
FAQ
What is the fastest way to cut damages
Post a short packaging matrix and enforce scan at pack. Start audits on your top movers first.
How do I know if a mailer is enough
Run a quick drop test with the real product and dunnage. If corners dent or parts shift, use a small carton.
What about fragile or liquid items
Use inner protection, seals, and leak-proof bags. Keep liquids upright in fitted cartons.
How do I keep returns from clogging outbound
Separate returns from outbound. Triage, then restock or quarantine within 24 hours.
What accuracy should we target
99.7 percent or better. Separate look-alikes, add a second scan at pack, and audit risky bins daily.