Packaging best practice: how to avoid parcel delays with Australia Post
- Apr 17
- 3 min read
For online sellers, fast delivery is not just about choosing the right carrier. How you package your parcels plays a major role in how quickly they move through sorting facilities.
After visiting Australia Post’s Melbourne Parcel Facility and Sunshine West Parcel Delivery Centre, we saw firsthand how small packaging mistakes can slow parcels down or even remove them from automated processing.
This guide shares practical packaging best practice tips to help you avoid delays and keep your orders moving efficiently.
Table of contents
1. Why packaging best practice matters Modern sorting facilities rely heavily on automation. Parcels move quickly along conveyor belts while scanners read labels and route them to the correct destination.
If a parcel cannot be scanned easily, it is removed for manual handling. This adds time, increases labour, and delays delivery.
Following packaging best practice helps:
Reduce handling delays
Improve scan success rates
Keep parcels moving through automated systems
Deliver a better customer experience
2. Common packaging mistakes that cause delays
Many delays come down to a few avoidable issues.
2.1 Label visibility and damage
Avoid covering QR codes and barcodes
Do not crease or fold labels
Do not place labels over box joins or edges
Do not tape over labels, even if it seems protective
Tape can reflect light and make scanning difficult. If the label cannot be read, the parcel is removed for manual processing.
2.2 Using plastic sleeves or label covers
Avoid plastic pockets or covers over labels (unless it's an international parcel with multiple label copies that need to go inside plastic pockets)
These are not necessary and can interfere with scanning accuracy.
2.3 Poor label placement
Do not place labels on uneven or curved surfaces or across box/tape joins
Avoid placing labels where branding makes them hard to distinguish
Machines work best when labels are clearly visible and isolated.
3. How to label parcels correctly Correct label placement is one of the most important parts of packaging best practice.
3.1 Place labels on the largest flat surface and keep a clear label zone.
This ensures:
Smooth movement along conveyor belts
Consistent positioning for scanners
Faster and more reliable reads
3.2 If your packaging includes logos or branding, leave a blank, high-contrast area for the label and avoid busy designs behind the label. This helps machines quickly identify and read the label.
3.3 Secure the box, not the label. It is recommended you use tape to seal the box properly and do not tape over the label. A secure parcel protects the label from damage during transit.
4. Parcel shape and material considerations
Beyond labels, the physical shape and material of your parcel also impact sorting speed.
4.1 Avoid round or uneven parcels. Parcels that are round (affectionately referred to as ‘roly poly’ parcels) can roll on conveyor belts. They may fall off and require manual handling.
Where possible, keep parcels flat or ‘squared’ so they are stable on a flat surface.
4.2 Be mindful of black packaging; whilst black parcels are not rejected, they can blend into conveyor belts, which makes them harder for scanners to detect quickly and accurately 5. Business considerations for scaling shipping
As your ecommerce business grows, small inefficiencies become costly. Good packaging and label placement reduce the risk of parcels being pulled out of automation, which is where most delays occur.
Following packaging best practices helps you:
Reduce operational delays at scale
Minimise failed scans and reprocessing
Maintain reliable delivery timelines
Build trust with customers
For further guidance, it is worth reviewing the official Australia Post Freight Preparation Guide alongside these real-world observations.
Final thoughts
Packaging and label placement are often overlooked, but have a direct impact on delivery speed. By following simple packaging best practices like proper label placement, avoiding tape over labels, and keeping parcels flat, you can significantly reduce delays.
Small changes at the packing stage can make a big difference once your parcels enter a high-speed sorting environment. Focus on clarity, consistency, and simplicity, and your parcels will move through the system faster and more reliably.
