By BCI
25 June 2025For brands, that expectation creates real logistical and financial challenges. The solution? Smarter ecommerce packaging design that anticipates returns and minimizes the cost and complexity of getting products back.
Reverse logistics can quickly drain profits, especially when return rates for online purchases hover around 20%–30%. But when packaging is designed with returns in mind, brands can reduce waste, prevent damage, and deliver a better customer experience.
Too often, packaging is designed only for the outbound journey — delivering a pristine product to the customer’s door. But in reality, a significant percentage of those packages will make a return trip. When that happens, flimsy or single-use packaging can cause more harm than good. Products get damaged, boxes get discarded, and brands end up footing the bill.
Ecommerce packaging design should support two-way logistics. That means durable construction, easy resealing, and clear instructions for how to return items using the original box. These features reduce repacking effort, improve customer satisfaction, and protect your inventory on the return trip.
Designing for returns isn’t just about logistics — it’s also about sustainability. The increased use of packaging, the disposal of more materials, and the loss or damage of more items in transit all contribute to environmental impact.
That’s why forward-thinking brands are working with sustainable packaging manufacturers to develop eco-conscious packaging that performs across multiple touchpoints. Durable corrugated packaging, recyclable inserts, and dual-seal strips are all small upgrades that make a big difference. These improvements reduce material waste, eliminate the need for additional mailers, and support circular packaging goals.
At Buckeye Corrugated, Inc. (BCI), sustainability and functionality go hand in hand. As a 100% American-sourced and American-made manufacturer, BCI creates packaging that supports both environmental responsibility and supply chain efficiency. Every solution is tailored to consider both outbound and return logistics, helping brands deliver on customer expectations while staying true to their sustainability commitments.
Efficient ecommerce packaging design supports smooth returns by prioritizing durability, ease of use, and reverse logistics functionality.
Packaging that’s engineered for returns doesn’t have to sacrifice style. In fact, well-executed graphic packaging solutions can communicate your brand’s professionalism, even when the customer is sending something back.
Details such as double adhesive strips, interior return instructions, and QR codes for generating return labels are subtle yet effective ways to streamline the process. These thoughtful touches demonstrate to customers that your brand values their time and supports their needs, even after the sale is complete.
In addition to enhancing usability, graphic packaging solutions also reinforce the brand identity throughout the return journey. A box that’s easy to reseal and re-ship keeps your branding visible and intact across touchpoints, maintaining a polished and consistent image.
If managing returns in-house feels overwhelming, working with a contract packaging partner can be a game changer. These partners specialize in efficient, scalable packaging solutions that include return-ready features as part of their standard offerings.
With access to experienced designers, automation technologies, and streamlined logistics, contract packaging services can help brands reduce operational costs, minimize waste, and improve reverse logistics performance.
At BCI, our packaging design services are closely integrated with fulfillment expertise, meaning you get packaging that works well in both directions and delivers real business value.
Returns may be inevitable, but frustration doesn’t have to be. The brands that stand out are those that make the process easier for everyone involved, from customers to warehouse teams. That starts with a smarter ecommerce packaging design that’s built for flexibility, durability, and ease of use.
As reverse logistics continues to impact profit margins and customer loyalty, packaging is no longer just a box; it is a crucial component. It’s a strategic tool that can improve sustainability, reduce costs, and elevate the post-purchase experience.
Looking to improve your returns process and reduce reverse logistics headaches? BCI offers intelligent ecommerce packaging design and end-to-end packaging design services that balance brand appeal, durability, and ease of use. With 100% American-made operations and a strong focus on sustainability, BCI provides custom contract packaging and graphic packaging solutions tailored to the demands of modern ecommerce.
Partner with a sustainable packaging manufacturer that understands the full journey, outbound and return. Contact BCI to discover smarter packaging solutions that enhance your customer experience and improve bottom-line performance.
