Packaging solutions for online retail and e-commerce

For online retailers and fulfilment operations, FUCHSPACK develops shipping packaging that delivers three things at once: fewer transit damages and returns, faster packing stations and less empty space. To achieve this, we combine paper cushioning and air cushion systems that produce the cushion directly at the packing station with precisely fitting custom boxes, and for sensitive goods with airbag or foam packaging. The result: a lower breakage rate, shorter packing time per shipment and packaging that meets the 50 % empty-space rule of the EU Packaging and Packaging Waste Regulation (PPWR).

Online retail keeps growing, and with it the number of shipments that have to reach the end customer quickly, cheaply and undamaged. Fast delivery is a key success factor, particularly for products with low to medium protection requirements. That calls for packaging logistics that save seconds at the packing station without letting breakage, returns and volumetric weight eat into your margin.

We develop customised packaging solutions for the demands of online retail: highly automated paper cushioning and air cushion systems that fill voids in a fraction of the time, precisely fitting custom boxes to keep air out of the parcel, and airbag or foam packaging for sensitive product ranges. We examine your packing station on site and put the cost-benefit calculation per shipment down in black and white.

What does online retail demand of shipping packaging?

Packaging decision-makers in e-commerce optimise four levers at the same time: damage, time, volume and material.

Transit damage and returns Every damaged shipment costs return postage, inspection and a replacement delivery, usually many times the cost of the cushioning that would have prevented the damage.
Packing time per shipment Trips to the materials store, cutting to size, switching materials: seconds per parcel add up to hours per day. Cushioning should be produced at the packing station, not carried to it.
Volumetric weight and empty space Oversized boxes cost freight and void fill, and from 2030 they will breach the 50 % empty-space rule of the PPWR, under which void fill counts as empty space.
Changing product ranges Many item sizes, seasonal peaks, temporary staff at the packing station: the system has to work without training and without changeovers.
Sustainability as a customer expectation Customers notice the material and the quantity. Recyclable cushioning and correctly sized boxes are part of your brand image, and part of your compliance.

Which packaging solutions are suitable for online retail?

In e-commerce, speed at the packing station comes first, with no compromise on protection. Our combinations:

Paper cushioning on demand at the packing station

Systems such as ProPad or PaperEZ Bubble produce cushioning in seconds directly at the packing station, for wrapping, cushioning and void fill. Recyclable in the paper loop and economical with material.

Go to paper cushioning

Air cushions for lightweight goods and void fill

Fill Air Rocket and NewAir I.B. Flex fill empty space with up to 30 metres of air cushioning per minute: lightweight, compact to store and quick to handle.

Go to air cushion packaging

Custom boxes against empty space

Precisely fitting boxes reduce volumetric weight, void fill and the risk of damage: the first lever for the PPWR empty-space rule and for your freight costs.

Go to custom boxes

Airbag and foam packaging for sensitive product ranges

Electronics, glass, cosmetics or wine: UNIQBAG airbags and INSTAPAK foam cushions protect fragile items with a form-fitting hold, even when formats change.

Go to airbag packaging

Typical product ranges we package for online retail

Electronics, accessories and small appliances
Cosmetics, glass and bottles
Spare parts, tools and technical supplies
Household goods and decorative items
Mixed shipments with varying item sizes
Fulfilment for marketplaces and brands

How packaging optimisation with FUCHSPACK works

Five steps – from the on-site analysis to roll-out, with no risk to your day-to-day shipping.

On-site consultation We look at your products, packing stations and shipping routes – and record the conditions of your processes.
Development and testing in the packaging lab Together we define the protective packaging and test it with your original product.
Cost-benefit calculation Packing time, material, freight and damage – all figures in black and white as proof of success.
Trial order You receive the system including material on trial and test it in live operation.
Roll-out and update service Only once you are convinced do we close the deal. On request, we check every two years whether everything is still at its optimum.

Benefits you will want to unpack!

Benefit from FUCHSPACK's dual expertise: we combine effective product protection inside the packaging with maximum efficiency in your packaging processes.

Cost-effective solutions

Inefficient packaging processes are expensive. We analyse the workflow and develop a cost-effective solution.

Update service

Packaging processes change. On request, we check every two years whether everything is still running at its optimum.

Time savings

With our solutions, even for complex geometries, improvised "home-made" packaging is a thing of the past.

Fewer complaints

Effective product protection inside the packaging. Our solutions fit the shipped goods like a second skin.

Frequently asked questions: packaging for E-commerce

With cushioning systems that produce the material directly at the packing station, i.e. paper cushioning or air cushions on demand. There is no trip to the store, and the cushion is produced to fit. During the on-site analysis we measure your current packing time and calculate the effect for you.

From 2030, shipping packaging may contain no more than 50 % empty space, and void fill counts as empty space. The most effective lever is a precisely fitting box, followed by cushioning with as little volume as possible. We take both into account in every e-commerce solution.

That depends on the product range; a look at the reasons for returns will quickly tell you. If breakage, scratches or dents are frequent, the cause lies in the shipping route, and that is where we start with the box, the cushioning and the fixation.

Yes. After the analysis we deliver the chosen system, including material, to your packing station on a trial basis. Only once time, protection and costs are right do we conclude the contract.

Request a packaging consultation for your online shop

Leave us your contact details and we will get in touch personally, talk about your product range, shipment volumes and your biggest headaches at the packing station, and propose an appointment.

Or contact us directly: +49 (0) 21 73-916 33-0 · verkauf@fuchspack.com

For more than 30 years we have been developing protective packaging for industry and retail – with on-site consultation and testing in our own packaging lab in Langenfeld, Germany.

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