6 Most Common Small Parcel Shipping Mistakes in the U.S.

Shipping small parcels in the United States may seem simple — attach a label, hand it to the carrier, and wait for delivery.

However, in real-world practice, extra fees, delivery delays, and returned packages happen.

Below are the 6 most common mistakes we’ve identified for your reference.

Mistake #1: Incorrect Measurements — Underestimating Box Size

It’s common to:

• Only measure the box without including external packaging

• Have actual dimensions larger than what was declared

These mistakes can lead to:

• Additional Handling Fees

• Large Package Surcharge

• Shipping costs doubling

Tip: U.S. couriers will re-measure packages. When filling out the shipping label, make sure to accurately measure both the package size and weight.

Mistake #2: Ignoring Dimensional Weight (DIM Weight)

Many people assume a light weight means low cost, but shipping charges are based on whichever is greater: actual weight or dimensional weight.

For example:

• Actual weight: 8 lb

• Box size 14×14×10 in → dimensional weight = (14×14×10) / 139 = 14 lb

• Charged weight = 14 lb, not 8 lb

Tip: Larger packages — even if light — may cost more due to dimensional weight.

Mistake #3: Wrong or Incomplete Address

Small parcels are often returned because of address issues.

Common problems include:

• Missing apartment or suite number

• Incomplete ZIP code

• What appears to be a business address is actually residential

These problems may result in:

• Address Correction Fees

• Delivery Exceptions

• Packages returned to the sender, requiring a second shipment

Tip: Double-check address accuracy and whether the delivery is residential.

Mistake #4: Poor Packaging Causing Damage or Return

Common packing errors:

• Using weak boxes for heavy contents

• Not filling empty space

• Failing to label fragile items

Possible outcomes:

• Damaged goods not covered (no compensation)

• Customer refusal

• Harm to your reputation

Tip: Carriers are not responsible for damage due to inadequate packaging.

Mistake #5: Ignoring Delivery Exceptions

In reality, delivery issues may include:

• Tracking shows a notice sticker that the recipient didn’t see

• Gated communities or building access problems

Possible results:

• Package returned

• Package held at facility (and if unclaimed for a week, returned to sender)

Tip: Don’t just check if the item was shipped — keep monitoring for delivery exceptions. 

Mistake #6: Only Comparing Price, Not Post-Sale Support

Common issues:

• No customer support when problems arise

• Long or complicated claims process

• No assistance resolving billing disputes

Tip: For small parcels — especially when shipping frequently — service quality matters more than the lowest price. 

Summary: The Real Cost of Small Parcel Shipping Is Mistakes

In U.S. small parcel shipping:

• A one-inch size difference can trigger extra fees

• One wrong address digit can mean a return

Spending 5 minutes checking before shipping is better than fixing problems afterward. 

Before Shipping Small Parcels, Verify These 4 Things:

1. Are dimensions accurate?

2. Will dimensional weight apply?

3. Is the address complete?

4. Are there potential surcharges to consider?