Christmas might still feel a long way away, but for UK e-commerce businesses and retailers, August is one of the best times to start preparing for the festive rush.

Once September arrives, Black Friday, Cyber Monday and Christmas can come around remarkably quickly. Order volumes increase, couriers become busier and suddenly something as simple as running out of the right cardboard boxes can become a serious problem.

Preparing your packaging early gives you time to review what worked last year, test different box sizes, plan stock levels and even introduce festive packaging before peak season begins.

At ASC Direct, you can also add our Christmas snowflake print to custom-sized boxes through our online BoxBuilder, helping turn an everyday delivery box into part of the Christmas customer experience.

Why should businesses start thinking about Christmas packaging in August?

The simple answer is time.

August gives you the opportunity to make packaging decisions while there's still plenty of time to test them.

Rather than discovering problems when order volumes are at their highest, you can use the quieter months to ask:

• Are our current boxes the right size?
• Are we using too much void fill?
• Which box sizes do we use most frequently?
• Did we run out of packaging last Christmas?
• Could packing orders be quicker?
• Could our packaging look better when it arrives?
• Do we need stronger boxes for particular products?
• Would festive printed packaging improve the customer experience?

Solving these questions now can make life considerably easier when peak season arrives.

Look at what happened last Christmas

Last year's Christmas period is one of the best places to start.

Look at your packaging usage between October and December and identify the boxes you used most frequently.

Were there particular sizes you repeatedly ran out of?

Did your packing team regularly have to use boxes that were too large because the correct size wasn't available?

Did you use excessive amounts of paper or other void fill?

Were certain products regularly damaged?

These are all signs that your packaging range could be improved before this year's Christmas rush.

Make sure you're using the right size boxes

Christmas orders can involve a huge variety of products, which makes it tempting to keep a small selection of large boxes and use them for everything.

But oversized packaging can create unnecessary costs.

If your box is considerably larger than the product, you may need more:

• Cardboard.
• Void fill.
• Packing time.
• Storage space.

Larger parcels can also potentially increase delivery costs where couriers use dimensional or volumetric pricing.

A made-to-measure cardboard box allows you to choose packaging much closer to the dimensions of your products.

That can be particularly valuable during Christmas when even small improvements in packing efficiency are multiplied across hundreds or thousands of orders.

Test new box sizes before peak season

One advantage of preparing in August is that you don't have to make a huge commitment immediately.

ASC Direct manufactures custom-sized cardboard boxes from just 25 units.

That means you can test a new box size with your products before deciding whether to order a larger quantity for Christmas.

You can check:

• How quickly the box can be packed.
• Whether the product fits correctly.
• How much protective packaging is required.
• Whether the box provides sufficient protection.
• How it works with your courier.
• How customers respond to the packaging.

Once you're happy with the specification, you can then consider ordering a larger quantity ahead of peak season.

When should you increase your order quantity?

Low minimum quantities are useful when testing packaging, but Christmas is also a time when ordering larger quantities can make commercial sense.

If you know a particular box size will be used consistently throughout November and December, increasing the quantity can help reduce the cost per box.

A larger order may be worth considering when:

• Your Christmas sales volumes are predictable.
• You've already tested the box size.
• You have sufficient storage space.
• The packaging won't change before Christmas.
• The saving per box justifies holding additional stock.

The key is finding the right balance between unit cost, storage space and cash flow.

Turn your delivery box into Christmas packaging

Christmas also gives online retailers an opportunity to make packaging feel more special.

Customers aren't simply receiving another online order.

They could be opening a Christmas present for themselves or receiving something they've purchased as a gift for someone else.

ASC Direct's BoxBuilder allows customers to add a Christmas snowflake print to their custom cardboard boxes.

It's a simple way to give your packaging a festive appearance without changing the fundamental box you use to protect your products.

For online retailers that don't have a physical shop, the delivery box is also one of the few physical interactions a customer has with the brand.

Making that experience memorable can make a difference.

Could Christmas packaging help with gifting?

Absolutely.

If customers are buying your products as Christmas presents, presentation becomes particularly important.

A festive printed shipping box can immediately make an order feel more seasonal when it arrives.

It can work particularly well for businesses selling:

• Gifts.
• Clothing.
• Beauty products.
• Food gifts.
• Toys and games.
• Homeware.
• Books.
• Subscription boxes.
• Handmade products.
• Corporate gifts.

And because the print is applied to the shipping box, there's no need to completely redesign your product packaging simply for the Christmas period.

Don't forget Black Friday

Christmas isn't necessarily the first peak you need to prepare for.

For many e-commerce businesses, Black Friday and Cyber Monday create a major increase in orders before December even begins.

That means packaging stock needs to be ready well before the Christmas shopping period reaches its peak.

Waiting until November to review your packaging can leave very little time to test different sizes, introduce new packaging or resolve problems.

Starting in August gives you breathing room.

Think about packing speed

When you're dispatching 20 orders a day, an extra 30 seconds packing each parcel might not seem particularly important.

When you're dispatching hundreds, it becomes a very different calculation.

Christmas is therefore a good time to look at how efficiently your boxes can be packed.

Ask whether staff are spending time:

• Cutting oversized boxes down.
• Searching for the correct box.
• Adding excessive void fill.
• Building complicated packaging.
• Reinforcing boxes that aren't strong enough.

Better-fitting packaging can make the packing process simpler and more consistent.

Make sure your boxes are strong enough

Christmas parcels often travel through extremely busy courier networks.

Choosing the appropriate board grade is therefore important.

Lightweight products may only require single wall corrugated cardboard, while heavier, larger or more vulnerable products may benefit from double wall board.

The correct choice depends on factors including the product's weight, dimensions, fragility and how the parcel will be transported.

The aim shouldn't be to use the strongest box possible for every order. It should be to use the appropriate box for the product.

Don't wait until you're running out

One of the easiest packaging problems to avoid at Christmas is simply running out of boxes.

Forecasting isn't perfect, but reviewing previous sales and packaging consumption can give you a sensible starting point.

It's also worth setting a minimum stock level for your most important box sizes.

That way, someone can reorder packaging before the final bundle of boxes is opened rather than after.

And if demand does exceed expectations, ASC Direct offers fast UK production options for custom-made boxes, including our 1-Day Express and 3-Day Standard services.

Responsible packaging at Christmas

Christmas can generate a significant amount of packaging, which makes avoiding unnecessary material particularly important.

Using a correctly sized cardboard box can help reduce excess cardboard and the amount of void fill required.

ASC Direct manufactures its cardboard boxes using FSC® Mix certified corrugated board under our FSC® Chain of Custody certification (FSC® C218342).

The corrugated board used to manufacture our boxes also contains a minimum of 70% recycled material.

Choosing the right-sized box alongside responsibly sourced materials gives businesses a practical way to think more carefully about their Christmas packaging.

Your August Christmas packaging checklist

Before peak season begins, consider:

• Review last year's packaging usage.
• Identify your most frequently used box sizes.
• Check whether you're using oversized boxes.
• Test made-to-measure alternatives.
• Review single wall versus double wall requirements.
• Forecast packaging quantities for Black Friday and Christmas.
• Decide when larger production quantities make financial sense.
• Consider introducing festive printed packaging.
• Establish minimum stock levels for essential boxes.
• Make sure staff know when packaging needs to be reordered.

Doing this in August gives you time to make changes before order volumes begin to increase.

Frequently Asked Questions

When should businesses order Christmas packaging?

Businesses should start reviewing their Christmas packaging requirements several months before peak season. August provides time to test box sizes, estimate quantities and make changes before Black Friday and Christmas demand increases.

Can I order custom Christmas boxes in small quantities?

Yes. ASC Direct manufactures custom-sized cardboard boxes from just 25 units, allowing businesses to test seasonal packaging before committing to larger quantities.

Can ASC Direct print Christmas boxes?

Yes. A Christmas snowflake print is available through the ASC Direct BoxBuilder, allowing businesses to add a festive appearance to custom-sized cardboard boxes.

Should I order more boxes for Christmas?

If your sales increase significantly during November and December, it's worth forecasting your packaging requirements in advance. For proven box sizes with predictable demand, larger quantities may also provide a lower unit cost.

Should Christmas shipping boxes be double wall?

Not necessarily. The appropriate board depends on the product's dimensions, weight and required level of protection. Lightweight products may be suitable for single wall cardboard, while heavier or more vulnerable products may benefit from double wall.

Why use custom-sized boxes at Christmas?

Custom-sized boxes can reduce unnecessary empty space and void fill while potentially improving packing efficiency. This can become particularly valuable when you're processing higher volumes of orders during peak season.

Get Your Packaging Ready Before the Rush

Christmas success isn't only about having enough stock to sell.

You also need enough packaging to get those orders safely out of the door.

Preparing in August gives you time to test, improve and order your packaging before Black Friday and Christmas demand begins.

Whether you need a better-fitting box, stronger packaging or something a little more festive, ASC Direct can manufacture custom cardboard boxes to your required dimensions from just 25 units.

And with our Christmas snowflake print available through BoxBuilder, your shipping boxes can become part of the festive experience too.

Start building your Christmas boxes today with ASC Direct.

James Palfrey-Smith is the General Manager at ASC Direct with extensive experience in both operations and sales. James is passionate about solving packaging problems, delivering fast customer support, and building lasting relationships. Outside of work, he enjoys outdoor activities like hiking and skiing. A fan of real ale and business podcasts, he continuously seeks personal and professional growth. 

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