Dead Weight

Dead weight is the weight of everything in your shipment that isn’t the actual product—boxes, packing materials, pallets, tape, and inserts. It’s weight you’re paying to ship but doesn’t represent sellable merchandise.

Components of Dead Weight

Outer packaging:

• Corrugated boxes (6-24 oz each)
• Mailers (1-4 oz)
• Pallets (30-70 lbs)

Inner packaging:

• Bubble wrap
• Packing peanuts
• Foam inserts
• Air pillows

Accessories:

• Tape (1-2 oz per package)
• Labels
• Packing slips
• Marketing inserts

Dead Weight Impact

Example:

• Product weight: 2 lbs
• Box: 8 oz
• Void fill: 4 oz
• Tape/labels: 1 oz
• Total ship weight: 2 lbs 13 oz
• Dead weight: 40%+ of total

At 3 lbs billable, you’re paying for nearly 1 lb of non-product.

Reducing Dead Weight

Optimize Box Size

• Use smallest box that protects product
• Consider custom-sized boxes for popular items
• Right-sizing can cut dead weight 20-40%

Lighter Packaging Materials

Eliminate Unnecessary Items

• Digital packing slips vs. printed
• Minimalist inserts
• Essential packaging only

Poly Mailers When Appropriate

• Weighs ounces vs. box pounds
• Ideal for soft goods
• Major dead weight reduction

Dead Weight Economics

For a business shipping 1,000 packages/month:

Annual savings: $12,000+ just from reducing dead weight.

Balancing Protection vs. Weight

Dead weight isn’t all bad—some is necessary:

• Adequate protection prevents damage
• Damage costs more than packaging
• Brand presentation matters
• Find the minimum for safe delivery

Dead Weight in Freight

For pallet shipments:

• Pallet weight (40-50 lbs) is significant
• Shrink wrap adds weight
• Choose lightweight pallets when possible
• Stack efficiency matters

Measuring Your Dead Weight

1. Weigh typical product
2. Weigh fully packed shipment
3. Calculate dead weight percentage
4. Benchmark against industry standards
5. Identify reduction opportunities