Common Mistakes and Smart Tips for Shipping with Regular Slotted Containers (RSC)

Why this matters

Even though Regular Slotted Containers (RSCs) are simple, beginners frequently make packaging mistakes that increase damage risk or shipping costs. This entry highlights common pitfalls and gives clear, actionable tips to improve performance with RSCs.

Top common mistakes

1. Using the wrong size box: Oversized boxes increase movement inside, requiring more void fill and increasing dimensional weight charges. Too-small boxes can crush or fail to close properly.
2. Insufficient internal protection: Assuming the box alone will protect the product often leads to damage. Fragile items need cushioning, foam, or dividers to avoid impact and abrasion.
3. Poor sealing technique: Only sealing the center seam or using weak tape can lead to openings or spills. Edge protection and proper tape width help keep boxes closed under stress.
4. Ineffective void fill: Using loose or crushed paper inconsistently allows shifting. The right void fill (air pillows, molded pulp, or foam) and correct placement prevent movement.
5. Ignoring stack load requirements: Stacking heavy boxes on top of weak RSCs causes crushing. Not accounting for warehouse stacking heights or pallet patterns leads to product loss.

Practical fixes—easy tips for better RSC performance

• Right-size boxes: Keep internal extra space to a minimum while allowing adequate cushioning—typically 1–3 inches on each side for non-fragile items.
• Use proper cushioning: Match cushioning to fragility: bubble or foam for shock-sensitive items, molded pulp for eco-friendly protective fits, and corrugated dividers for multiple items.
• Seal wisely: Use an H-tape pattern (three strips) for heavier boxes and ensure tape overlaps box edges. For high-value or heavy goods, filament tape adds tensile strength.
• Consider corner and edge protection: Cardboard edge protectors or corrugated partitions reduce crushing and protect sealed seams during pallet stacking.
• Document handling instructions: Print or apply clear labels for fragile, top-load only, or orientation-sensitive shipments to guide handlers and carriers.
• Test packaging under real conditions: Conduct simple drop and vibration tests in-house, and track damages to refine packaging choices over time.

Cost-saving strategies

• Minimize void space: Use right-sizing tools or software to automatically select the smallest RSC that fits the product and required cushioning.
• Choose efficient cushioning: Air pillows and honeycomb paper often give good protection for less weight and cost than bulky foam.
• Standardize SKUs: Reduce box types across SKUs to lower inventory complexity and take advantage of bulk pricing.

Handling and shipping tips

• Pallet patterns: Alternate box orientation on pallets to interlock layers and improve stability; use stretch wrap and banding where appropriate.
• Label placement: Place labels on the largest side panel and avoid seams; include barcode orientation to speed scanning.
• Monitor carrier requirements: Different carriers enforce rules for box strength and weight limits—check those to avoid surcharges or refused shipments.

Common troubleshooting scenarios

• Crushed corners on delivery: Upgrade to stronger corrugated grade, use corner protectors, and improve pallet stacking practices.
• Boxes opening in transit: Switch to wider tape, increase adhesive quality, or use H-pattern sealing. Consider internal strapping for very heavy contents.
• High return rates due to damage: Run root-cause analysis—identify whether damage happens in warehouse handling, transit, or at delivery—and iterate packaging design.

Beginner checklist to reduce errors

• Measure products and pick the right RSC size.
• Choose corrugated board grade based on weight and stacking needs.
• Specify appropriate cushioning and void fill.
• Seal with the right tape and pattern.
• Label clearly and follow pallet best practices.

Final friendly reminder

RSCs are forgiving and economical, but success comes from matching box size, board strength, and protective materials to the product and shipping environment. Start small: test a few configurations, track damage and shipping costs, and adjust. Small improvements in packaging choices often yield outsized savings and happier customers.