No matter how great your product is, a poor shipping experience can ruin customer trust, trigger returns, and cut into your profit margins. Many ecommerce sellers unknowingly make shipping mistakes that cost time, money, or both.

Here are the top 10 shipping mistakes online sellers make—and how to avoid them.

1. Using the Wrong Box Size
   Oversized boxes lead to inflated dimensional weight (DIM) charges. Carriers calculate shipping costs based on size and weight, so unused space costs you more.

Tip: Keep multiple box sizes on hand and train staff to choose the most efficient option.

2. Not Comparing Shipping Rates
   Sticking to one carrier out of habit often leads to overpaying. Services like Shippo, Pirate Ship, and Easyship offer live comparisons across USPS, FedEx, UPS, and DHL.
3. Overlooking Carrier Pickups
   Driving to the post office every day burns valuable time. USPS offers free pickups, which makes things a lot more convenient.
4. Not Taking Advantage of Free Supplies
   USPS, FedEx, and UPS all offer free branded shipping supplies when you use their services.

• Order USPS supplies here
• UPS supplies

5. Ignoring Packaging Weight
   Heavy filler materials like paper and bubble wrap can add up. Lightweight alternatives such as air pillows or compostable mailers from EcoEnclose help minimize postage costs.
6. Forgetting to Use Address Verification Tools
   Invalid addresses result in returned packages or costly address correction fees. Platforms like SmartyStreets and EasyPost help catch errors at checkout.
7. Not Factoring in Return Logistics
   Offering returns without a clear return shipping process can frustrate customers and strain your team. Use systems like Returnly or Loop Returns to manage return labels and restocking efficiently.
8. Failing to Offer Multiple Shipping Speeds
   Only offering standard shipping can lead to cart abandonment. Platforms like Shopify or BigCommerce allow you to integrate multiple shipping speeds and real-time carrier rates.
9. Underestimating the Value of a Thermal Label Printer
   Printing with inkjet printers and taping on labels is time-consuming. Thermal printers like Rollo and DYMO are faster, more durable, and cheaper over time.
10. Not Tracking Shipping Costs Monthly
    Without reviewing your shipping expenses, it’s easy to lose track of rising costs. Use accounting tools like QuickBooks or simple spreadsheets to analyze shipping spend by carrier, product type, or customer region.

Conclusion

Avoiding these common mistakes can significantly improve your shipping workflow and customer satisfaction. From using the right supplies to comparing real-time rates, small adjustments add up quickly. Take the time to assess your process and implement smarter practices now, so your fulfillment doesn’t become a barrier to growth.