I am always interested to see what kind of unique packaging materials people use. As a conservationist and environmentalist, I am always trying to come up with ways to use natural or recycled packaging materials.
With fall coming, I am reminded of how great dried fallen leaves work to cusion and protect many items. As a buyer, I would probably be upset to open a package and have the leaves from your back yard fall all over my living room BUT if you stuff plastic grocery bags with leaves and tie them they can make great cushions and very inexpensive packing! ( Wet leaves are not ok to use as they create mold, smell bad, and add significant weight to your package)
I cannot stress how important it is to protect fragile items from the inside. If there is any way to fill the inside of a fragile item, do it.!I have occasionally had to package small bud vases and found that stuffing them with toilet paper (not used) was a great way to fill them to absorb transferred shock. However, I would not do this if the item cannot be immersed in water as it can be difficult to remove all that toilet paper unless you can wet it. Once wet, the toilet paper is easily removed. I would also send a little note to explain that to your buyer.
The lightweight plastic containers that some snacks come in are great for floating small items in. Molded plastic containers can really help protect fragile pieces and don't add more than an ounce or two to the total weight of your pack. One or two liter soda bottles are great inner containers when you cut the tops off. And, if the box you have is a bit too large for your item, don't be afraid to use an egg carton or two, or a cleaned out, empty potato chip tube to fill voids.
Every day people toss out great potential packaging materials. If we all look for alternative packaging solutions, we might save ourselves a little money and help keep our planet safe for humans.
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