The Challenge
An outdoor gear company specializing in mid-weight, high-value products—like trekking poles, harnesses, and carabiners—was losing money and reputation due to poor packaging. Their orders were arriving damaged far too often, leading to returns, negative reviews, and extra customer service hours.
The issue wasn’t just the box. Their setup consisted of stock corrugated boxes from thin cardboard (flute E) that didn’t fit their products well, plain tape that wouldn’t hold in colder warehouse conditions, and no real branding or structure inside the packaging to protect the gear.
They needed a full revamp—custom packaging solution that would both survive transit and reflect the premium feel of their product line.
Plus Packaging Solutions
After being referred by their fulfillment partner, the brand connected with Plus Packaging to figure out a fix. It wasn’t a one-size-fits-all project—we worked through a mix of custom packaging components built around their specific gear and workflow.
Shipping Boxes Built for Stress
We started by analyzing their current shipments and requested actual product samples. Our team ran drop tests, measured flex under load, and built custom dielines to tighten the internal fit of each box. The final design used reinforced double-wall (flute B) cardboard for heavy items, keeping gear locked in without extra fill or overpacking.
Click here to learn more about Custom Shipping Boxes!
Printed Tape That Holds (and Looks Right)
Their original tape was tearing or letting go during shipping—especially when applied in cooler temperatures. We replaced it with heavy-duty custom printed tape designed for high-tack adhesion on their exact board stock. Not only did it seal better, it elevated the look of the box instantly.
Click here to learn more about Custom Printed Tapes!
Branded Hang Tags That Match the Product Feel
Hang tags were produced on thick, tear-resistant matte paper with reinforced grommets. These weren’t just decorative—they carried use instructions and safety warnings, so they had to survive both shipping and shelf handling.
Click here to learn more about Custom Hang Tags!
Results and Takeaways
The brand saw immediate results:
- Product damage dropped by nearly 70%
- Packing time was reduced thanks to better-fit boxes and stronger tape (no need to double-seal)
- More customers shared their unboxing experience, often tagging the brand from outdoor locations
- Zero box failures reported across 2,000+ shipments in the first three months
What made it work wasn’t just the packaging—it was the process. We built the solution around their product, not the other way around. The Plus Packaging team worked directly with the brand to prototype, adjust, and deliver packaging that solved the core problems while boosting perceived value.
Even though the brand can’t be named due to confidentiality, this project shows what’s possible when durability, presentation, and execution are all handled with care.
Why eCommerce Brands Trust Plus Packaging for Durable, Custom Packaging Solutions
At Plus Packaging, we know that for gear brands, packaging isn’t just about looks—it’s about trust. It needs to survive drops, moisture, temperature shifts, and warehouse chaos without giving up on presentation. That’s why we don’t just print boxes—we build real solutions that work in the wild.
Whether you’re shipping carabiners, tents, or energy bars, we bring the materials knowledge, flexibility, and communication needed to deliver packaging that protects and sells at the same time. Let’s solve your next packaging challenge — together.
📦 Get a custom quote and shipping-ready plan in 48 hours.
📅 Speak directly with our packaging experts—no middle steps.
🔁 Count on a long-term partner who gets it done right.
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