When you consolidate packages, you combine multiple items into one shipment. If a customer orders three products, they get one box instead of three.

Sometimes this means packing multiple items from one order together. Sometimes it means bundling items from different retailers into a single overseas shipment. Either way, the goal is to reduce waste and cut costs.

The benefit? You pay for shipping once, not three times. And your customer gets a better experience.

How Package Consolidation Works (Step-by-Step Breakdown)

Whether you manage fulfillment yourself or use a 3PL, here’s how the process goes:

1. Collect All Items

In-house: gather all parts of the order.
At a 3PL: receive packages from various sellers headed to the same person.

2. Inspect and Sort

Check for damage. Confirm what goes together. Decide the best way to pack them.

3. Repack into a Single Box

Strip away excess packaging, add protective filler, and use a sturdy, right-sized box. Avoid overpacking—dimensional weight charges can kill savings.

Some sellers even design packaging with compartments just for accessories. That’s consolidation with foresight.

4. Ship as One Package

Now you’ve got one label, one tracking number, one delivery. It’s smoother for carriers, easier for customers, and cheaper for you.

Domestic vs. International: What’s Different About Consolidation Across Borders?

• Domestic: Mainly used to fulfill multi-item orders in one box.

   

• International: Often involves holding shipments from multiple stores until they all arrive, then sending them together.

   

Bonus perk: international consolidation simplifies customs paperwork. Just watch for duty thresholds, one big box might cost more in taxes than separate shipments.

Why Consolidating Packages Saves Money

Shipping carriers charge by weight, size, and number of boxes. Package Consolidation saves money by attacking all three.

Pay Once, Ship More: Avoiding Duplicate Fees

Every box has base fees pickup, fuel, residential delivery. Ship three boxes? You pay those three times. Combine them? Pay once.

Bigger Is Cheaper (Sometimes): Explaining Rate Tiers

Two 5 lb boxes often cost more than one 10 lb box. Consolidation can push you into better rate brackets.

In freight? Going from less-than-truckload (LTL) to full truckload saves 25–35%. Similar rules apply to parcels: fuller trucks cost less per item.

Fewer Boxes = Fewer Surcharges

Delivery area fees, fuel surcharges they’re all per package. Consolidate, and you only pay once.

If you’re sending lots of orders to the same region, consider zone-skipping: bulk ship to a regional hub, then inject locally. Many 3PLs do this already.

How 3PLs Like eFulfillment Service Cut Bulk Shipping Costs

Through programs like SaverShip, we pool orders from many clients, then ship them as one big batch.

• 20 lb box: ~67% cheaper than USPS 
• 50 lb box: ~80% cheaper than FedEx 
• One client ships 9 lb items for under $8 via SaverShip 

You won’t get those rates on your own. That’s the power of consolidated volume.

Less Packaging, Less Labor, Less Overhead

Three boxes mean three sets of tape, filler, labels, and time. One box? That’s two steps skipped—and a leaner operation.

The “Free Ride” Trick: Maximizing Dimensional Weight

Already paying for a big, mostly empty box? Toss in a small item without raising your rate.

Example: Shipping an inflatable kayak in a large box with dimensional weight charges? That paddle or air pump can often “ride free.”

Just make sure the extra item doesn’t bump you into a higher tier. Otherwise, the savings vanish.

More Than Just Cost Savings: Extra Benefits of Package Consolidation

There’s more to consolidation than lower rates. It also makes your customers (and your ops team) a lot happier.

Fewer Deliveries, Happier Customers

Split orders create confusion. One box = one tracking number = one complete delivery. It’s clean, predictable, and boosts customer satisfaction.

Simpler Logistics and Easier Order Management

Your team tracks fewer shipments. Customers ask fewer “where’s my stuff?” questions. Everyone wins.

Eco-Friendly Shipping That Cuts Packaging Waste

Fewer boxes = less cardboard, less plastic, fewer truck miles. Consolidation can reduce carbon emissions by up to 40%. That’s real impact.

And if you market your eco-conscious shipping? That’s a brand bonus.

Faster Fulfillment With Fewer Delays

Fewer packages = fewer handoffs = fewer chances for things to go wrong. One box gets delivered faster than three staggered ones.

Zone-skipping and regional freight? Even faster.

Smarter Inventory and Bundling Tactics

If customers always buy shampoo and conditioner together, don’t keep packing them one by one. Kit them or have your 3PL’s kitting service do it for you.

One box, one SKU, one picking operation. Less work. Fewer mistakes. Better forecasting.

When NOT to Consolidate Packages

Consolidation isn’t perfect. Sometimes it costs you more. Sometimes it’s a pain. Here’s when to skip it.

Dimensional Weight Problems Can Wreck Your Savings

If combining items forces you into a larger box that’s mostly air, dimensional weight might hit hard. Always compare costs: one big box vs. two small ones.

Don’t Trigger Overweight Surcharges

Over 50 lbs? Expect handling fees. Over 70 lbs? It gets worse. These can erase any savings.

If combining turns two 40 lb boxes into an 80 lb behemoth, split it back up. Your warehouse team (and your budget) will thank you.

Some Items Just Don’t Pack Well Together

Don’t ship glass vases with kettlebells. Or anything fragile with anything heavy. If there’s a break risk, ship separately. It’s cheaper than replacing broken inventory.

Urgent Orders May Not Be Worth Waiting On

If one item is in stock and the other’s on backorder, waiting to consolidate can backfire. Give the customer the choice. Some will wait. Others won’t.

International Consolidation Can Mess With Customs

Group too much together and you might trigger higher import taxes or more paperwork. Some regulated products can’t even ship together.

Always check before you consolidate cross-border.

How to Consolidate Packages the Right Way

Want to make consolidation work? You’ll need more than tape and good intentions.

Start With Your Order Data

Find out how often you’re sending multiple boxes to the same customer. Run the numbers. A basic spreadsheet can help you calculate the real savings (or losses).

Use the Right Box Sizes (Seriously)

Don’t pack a necklace in a boot box. Having a variety of sturdy, efficient box sizes keeps dimensional weight low and contents safe.

Bonus: Design product packaging with built-in space for accessories. One client did this—and never looked back.

Bundle and Kit Common Combos

If items are usually bought together, pre-pack them into one SKU. This speeds up fulfillment and ensures automatic consolidation.

You’ll also increase your AOV and make restocking easier.

Automate Consolidation Rules in Your OMS

Most systems can flag multiple orders going to the same customer or address. Some sellers hold orders for 24 hours to catch second purchases.

Just make sure customers aren’t waiting too long. And confirm your 3PL knows how to handle these rules.

Use Regional Freight for Big Savings

Ship everything going to California together. Palletize it. Inject locally. That’s zone-skipping and it works.

Programs like SaverShip do this automatically for heavier ecommerce products. You benefit from lower long-haul rates and faster delivery times.

Know When to Switch From Parcel to Freight

Once your shipment hits 150+ lbs, it might be time for LTL freight. Pallets are safer, cheaper, and more efficient at that size. Talk to your 3PL.

Let Your 3PL Do the Heavy Lifting

Your 3PL has the data, tools, and experience to consolidate smartly. They might even suggest ideas you hadn’t thought of like combining SKUs or moving to freight.

Use them. That’s what they’re there for.