Have you ever looked at a return and thought, this should never have happened?

The product was fine when it left you. The customer still received a dented box, a broken unit, or a leaky mess. Now you are paying for three problems at once: refunds, replacements, and reputation.

This is why picking the right packaging boxes suppliers is not just a sourcing decision. It is a damage control decision. Flipkart Group faced the same issue at scale and changed the packaging system so it could protect products, stay consistent, and still move at e-commerce speed.

If you are seeing repeat damage returns, share your top 3 return photos and the product weight. Saaro can help you spot what is failing first.

The Returns You Are Seeing Are Not Random

Damage usually comes from patterns, not luck.

Your packaging fails in one of three places.

• The product moves because the box is oversized
• The protection varies because packing is inconsistent
• The outer pack weakens because moisture and handling stress break it down

Once that happens, you see the same outcomes again and again: dents, breakage, leakage.

Flipkart’s approach worked because they treated packaging as a repeatable system, not a last-minute patch.

What Flipkart Changed To Reduce Damage

Flipkart’s sustainability program included several changes that also improve transit performance. Three are worth paying attention to because they solve common damage triggers.

Consistent Void Fill That Stops Product Movement

Flipkart used shredding or meshing machines that convert corrugated boxes into mesh sheets used as void filler or cushion wrap. These machines were installed at major fulfilment centres, and the document notes that no material is procured for void fillers because cartons received from seller partners are recycled.

When void fill becomes consistent, product movement drops. Impact spreads out instead of hitting one corner repeatedly.

Security Bags Built To Handle Moisture And Handling

The case study describes security paper bags made from virgin Kraft paper with a registered heat seal coating and a water repellent coating for protection.

This matters because moisture is a silent destroyer. Packs soften, seals lift, corners weaken, then compression damage becomes unavoidable.

Smarter Use Of Secondary Packaging

Flipkart also pushed e-commerce-ready packaging, aimed at permanently reducing the need for a secondary layer and shipping in primary packaging based on product categories and geography. As of July 2021, Flipkart shipped 15 per cent of orders through e-commerce-ready packaging.

Less unnecessary outer packaging often means fewer awkward shapes, fewer crush points, and better stacking performance.

If your biggest issue is denting and corner crush, you likely need a stronger structure plus a tighter fit, not more filler. Saaro can help you fix that without making your packaging bulky.

The Numbers That Show Scale

This was not a tiny pilot. Flipkart reported clear milestones.

• January 2021: 15 per cent of products shipped without secondary packaging under the No Package Shipping program

• January 2021: 96 per cent of customer shipments from fulfilment centres were shipped in sustainable packaging

• June 2021: Flipkart achieved 100 per cent elimination of single-use plastic in its own supply chain, covering more than 70 facilities across India

Marketplace adoption also moved fast.

• As of September 2021, 85 per cent of total sellers made the switch to non-plastic packaging

More than 3 times the jump in sellers switching compared to July 2020. Around 20 times jump in units sent in sustainable packaging since the initiative began

What Sellers Said About Damage And Leakages

This is the proof that matters if you are fighting returns.

One seller shared that customer feedback improved after switching to cardboard boxes and that the new packaging drastically reduced in-transit damage, leading to a better customer experience.

Another seller said they saw improved return rate and customer feedback that helped offset the higher packaging cost, and they specifically noted a reduction in transit damage and fewer leakages.

The lesson is blunt: packaging cost is visible, return cost is hidden, and return cost is usually higher.

Why It Worked In Simple Terms

Flipkart’s changes worked because they nailed three fundamentals.

• Control movement inside the pack
• Protect the outer layer against moisture and handling stress
• Make packing repeatable so results do not depend on who packed it

That is why simply switching a material rarely fixes damage. The system matters.

Example Scenario For Electronics

Imagine you ship a premium smartwatch or earbuds. It does not arrive broken, but the retail box is scuffed, and the outer pack is crushed at the corners. The customer returns it anyway because, for electronics, cosmetic damage looks like mishandling.

This is where an electronics packaging box needs to do two jobs at once. It must lock the product in place so it cannot shift, and it must resist compression so stacking pressure does not transfer into corners.

At Saaro, the fix usually starts with three changes: a tighter fit, a designed insert that holds the device firmly, and an outer structure that matches the shipping risk. When those three work together, you stop bleeding returns from damage that is not even a product failure.

Example Scenario For Cosmetics

Now take a serum bottle or perfume. You might be using a good-looking outer box, but the inner holding is loose. During transit, the bottle taps the walls of the pack repeatedly. Even if it does not shatter, the cap loosens or the pump leaks. That leak stains the inside, smells strong, and the customer loses confidence instantly.

Here, the problem is rarely solved by adding more filler. It is solved by stopping movement and supporting the most fragile points, like the neck and the cap area. The difference between a clean delivery and a leaky return is often one well-designed insert and the right sealing approach.

How To Evaluate Packaging Boxes Suppliers Before You Switch

If you are shortlisting packaging boxes suppliers, do not only compare the price per box. Compare whether they can help you reduce your most common damage type across the right packaging box types for your category.

Here is a quick filter you can use.

• Can they right-size reliably so products do not move
• Can they engineer inserts so that protection stays consistent across batches
• Can they improve moisture resistance and sealing based on your shipping lanes
• Can they recommend the best type of packaging box for the actual handling risk, not just the shelf look

This matters even more if you are sourcing custom packaging boxes in India, because the real quality difference is not only printing. It is whether protection holds up when packed at scale.

How Saaro Applies The Same Logic to Your Packaging

Flipkart’s challenge was scale. Your challenge is brand experience plus returns. The physics are the same.

At Saaro, we work backwards from your damage pattern, then build the pack around three priorities: structure, fit, and holding. That is how we reduce returns without inflating packaging costs.

If you are comparing packaging boxes suppliers, Saaro’s edge is simple. We do not treat protection as an add-on. We design it from the start, then make sure it stays repeatable across production.

If you want fewer damage returns without adding unnecessary layers, a packaging boxes supplier like Saaro can help you redesign a protection-first pack and choose the right approach for your category. Contact us today!