Overflow packages are a common sight in e-commerce fulfillment centers. As online shopping continues to grow in popularity, more and more packages are shipped out every day. With increased volume comes the need for efficiency in packing and shipping. This is where overflow packages come into play.
What are overflow packages?
Overflow packages are additional packages created when an original package has exceeded the weight or dimension restrictions for its shipping method. For example, if a customer orders multiple heavy or large items that exceed the 50 lb weight limit for standard ground shipping, those items may be divided up into separate “overflow” packages. This allows each package to meet carrier requirements for the selected shipping method.
Overflow packages are typically created on the fly in fulfillment centers as orders are packed. They help maximize space and balance weight, while keeping each package within carrier guidelines. Having to split orders into multiple packages also allows companies to keep using economical shipping methods, rather than upgrading to costlier expedited services required for oversized packages.
Why do overflow packages exist?
There are a few key reasons why overflow packages are necessary in e-commerce order fulfillment:
- Carrier restrictions – Each shipping carrier sets dimensional and weight limits for their various shipping services. Exceeding these voids their rate quotes and requires upgrading to different shipping methods. Overflow packages prevent this issue.
- Optimization – Breaking orders into overflow packages allows for better space optimization in boxes, balancing weight, and using standard low-cost shipping services when possible.
- Automation – Many fulfillment centers use automated systems and robots that are designed for packages within standard sizes. Overflow packages allow orders to work with existing infrastructure.
While it may seem simpler to use one large box per order, this can create logistical issues that hurt both customers and companies. The strategic use of overflow packages helps e-commerce businesses ship orders efficiently and economically.
How are overflow packages created?
There are two main ways fulfillment centers handle overflow packages:
- Pre-planned overflow – For very large orders or bulky items, overflow packages may be planned upfront. The order management system can be configured to automatically divide these orders into multiple packages from the start.
- On-demand overflow – More often, overflow packages are created ad hoc as pickers pack orders in the fulfillment center. When a package exceeds carrier limits, additional boxes or bags are added to spread out the items.
The on-demand approach takes real-time problem solving as orders are processed. Packers have to assess size, weight, and quantity of all items in an order and decide how to optimally split them into overflow packages. This takes training, experience, and an understanding of shipping requirements.
What goes into an overflow package?
Overflow packages can contain a mix of items from an order. Determining what goes into each one depends on the specific items, packaging sizes, and weight. Some general strategies packers follow include:
- Heavier items go into separate overflow boxes to avoid overweight shipping packages.
- Smaller and lighter items are grouped together in one main package.
- Identical items are split evenly between packages.
- Fragile items may go into an overflow package with extra padding.
There is no universal rule on how to allocate items. The goal is to optimize each package for safe and efficient shipping. Often overflow packages have more padding than the original, since they contain fewer items. Packaging inventory and creativity both come into play when splitting orders.
Do overflow packages have tracking?
Yes, each overflow package receives its own tracking number and scans just like regular packages. This allows customers to track the status of all their packages from an order. Overflow packages shipped via major carriers like UPS, FedEx, and USPS are fully trackable.
Some tips on tracking overflow packages:
- Tracking numbers for all packages in an order should be provided together or linked in shipment details.
- If one package is delayed or lost, it won’t affect tracking of other overflow packages.
- Customers should be instructed to check tracking for all packages to see their complete order status.
Providing full visibility into each overflow package improves the post-purchase experience for customers.
Do customers get notified about overflow packages?
In most cases, customers should be clearly notified at checkout or in shipping confirmation emails if their order is being split into multiple overflow packages. Reasons notification is important include:
- Sets expectations about receiving multiple packages instead of just one.
- Allows customer to more accurately track status of entire order.
- Reduces customer confusion or concerns if additional packages start arriving.
- Lets customers know upfront if delivery dates may vary based on package contents.
Some merchants even show which items are allocated to each package identified as “Box 1 of X” so customers know what is coming in each shipment.
Do overflow packages cost more?
In most cases, there are no additional charges to the customer for overflow packages. The packages are a fulfillment strategy that allows merchants to contain shipping costs. Reasons include:
- Using overflow packages allows lower cost ground services rather than upgrading to expensive expedited shipping.
- Merchants will often absorb small incremental costs of additional packages to retain their standard shipping rates.
- Overflow packages help merchants optimize box space and stay within dimensional weight limits.
The only scenarios where overflow package fees may apply:
- International shipments where duties are charged per package, not per order.
- Cases where oversize or overweight item fees still apply to a package.
- A merchant applies a small split shipment or handling fee to offset labor costs.
But in general, overflow packages help avoid incremental charges rather than create them.
Do overflow packages affect delivery time?
Whether overflow packages impact delivery timelines depends on a few factors:
- Carrier differences – If overflow packages travel via different carriers, delivery dates can vary based on each carrier’s transit times.
- Separate dispatches – Overflow packages shipped from different fulfillment centers or on separate dispatch days may arrive on different dates.
- Destination differences – For multi-stop shipments, like drop shipping, overflow package transit times may differ based on destination.
Under typical circumstances where overflow packages all ship together via the same carrier to one address, there should be minimal impact on delivery time compared to one package.
Do overflow packages have different labels?
Overflow packages will be labeled and barcoded for tracking and sorting purposes as they travel through the shipping network. The label on overflow packages often differs from the main package in small ways:
- Unique package IDs like “Box 1 of 3” are added to distinguish from other packages in the order.
- The label may omit customer order details that are only on the main package label.
- Overflow package labels focus mainly on logistic details like addresses, tracking, and handling.
But all overflow packages related to one order should have the same shipper and recipient addresses so they arrive at the right place.
Best practices for overflow packages
Some tips for seamlessly integrating overflow packages into order fulfillment and delivery:
- Group items intelligently into packages to optimize weight limits, dimensions, and item protection.
- Use an order management system that handles package allocation automatically.
- Select packaging sizes strategically based on common overflow situations.
- Train warehouse staff on overflow procedures and how to split packages efficiently.
- Notify customers about multi-package shipments and provide all tracking numbers.
- Use package identifiers like “Box 1 of 3” to distinguish overflow packages.
- Consider flowers or gifting items for overflow packages to improve unboxing.
With proper processes and communication, overflow packages can seem like bonus gifts rather than inconveniences for customers. The fulfillment advantages outweigh the minor downsides.
FAQs about overflow packages
Here are answers to some frequently asked questions about overflow packages:
| Question | Answer |
|---|---|
| Why don’t merchants use one big box instead of overflow packages? | One large box costs more to ship and doesn’t work with fulfillment center automation designed for smaller packages. Overflow packages optimize shipping. |
| How many overflow packages can an order be split into? | There is no set limit – orders can be split into as many packages as needed to contain items within shipping weight and size limits. |
| Can I refuse an overflow package I don’t want? | Technically yes, but it can disrupt and delay delivery of the full order. Best practice is to accept all packages and return any unwanted items. |
| Who decides what goes into each overflow package? | Warehouse pickers decide how to optimally split an order while packing it based on experience and training. |
| How will I know an order has overflow packages? | You should receive clear notification from the merchant at order confirmation or shipping that the order uses multiple packages. |
The role of overflow packages in modern e-commerce
As online shopping scales up, overflow packages have become an indispensable part of order fulfillment. They enable merchants to keep using affordable ground shipping for large orders and optimize space utilization in packages.
For customers, it means occasionally having the fun of opening multiple packages from the same order. This used to be seen as an inconvenience, but smart merchants now use overflow packages strategically to enhance unboxing while controlling costs. With better customer education and visibility into multi-package shipments, any downsides can be minimized.
Overflow packages are likely here to stay as e-commerce grows. Their benefits for fulfillment process efficiency and sustainability outweigh the small tradeoffs. By mastering the details of overflow packages, both businesses and customers can enjoy a smooth modern shopping experience.
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