--- title: Unexpected Packaging Pitfalls You'll Never See Coming description: Custom designed packaging from your packaging partner to help avoid unexpected packaging pitfalls. image: https://www.ashtonne.com/hubfs/Ashtonne%20Unprepared%20with%20papers%20covering%20rain.png --- [![ashtonne packaging company](https://www.ashtonne.com/hs-fs/hubfs/Logos/ashtonne_logo.png?width=328&height=112&name=ashtonne_logo.png "ashtonne packaging company")](https://ashtonne.com/) [Request More Information ](https://www.ashtonne.com/surveys/creative-packaging-ideas-and-solutions) [877-522-6937](tel:8775226937)   × # Unexpected Packaging Pitfalls You'll Never See Coming - [** ](https://www.facebook.com/AshtonnePackaging/) - [** ](https://www.twitter.com/Ashtonne_pkg) - [** ](http://pinterest.com/ashtonne8775226937/) - [** ](https://www.linkedin.com/company/11170776) - [** ](https://www.youtube.com/channel/UCpVPPbg_6lPaoNol_G6PuPQ) ![Unexpected Packaging Pitfalls You'll Never See Coming](https://www.ashtonne.com/hubfs/Ashtonne%20Unprepared%20with%20papers%20covering%20rain.png) ** [Bill Madl](https://www.ashtonne.com/blog/author/bill-madl) ** Posted on November 02, 2025 | Updated on November 10, 2025 ## What could go wrong for business even when everything else goes right. Most business owners think about packaging as a way to protect their product and present their brand, which it absolutely is. But what many don’t see are the countless moving parts that happen behind the scenes to make sure that protection, presentation, and delivery all happen on time, every time. That’s where things often go wrong, not because of bad intentions, but because of what you can’t see until it’s too late. We’ve seen those moments. And over time, we’ve learned how to stop them before they start.  Here are a few things to watch for.  We know them well, because we are watching for them right now. ### The Perfect Box That Wasn’t Every now and then, a product’s packaging looks fantastic in the design room but fails in the real world. Maybe it can’t handle stacking pressure. Maybe humidity weakens the adhesive. Maybe the supplier changed board quality midstream. What looks “perfect” in theory can turn into crushed corners, damaged goods, and disappointed customers in practice. At [Ashtonne Packaging,](https://www.ashtonne.com/) we test, verify, and stress the details because a box that just *looks good* isn’t enough. ###   **I**nventory: Too Much, Too Little, or Too Late ### **![custom designed packaging in a warehouse](https://www.ashtonne.com/hs-fs/hubfs/undefined.jpeg?width=288&height=135&name=undefined.jpeg)** There’s a sweet spot in [packaging inventory,](https://www.ashtonne.com/blog/benefits-of-a-vendor-managed-inventory) and it’s rarely guessed right. Having too much packaging ties up cash and shelf space. Having too little stalls production. And missing delivery windows altogether can throw off entire supply chains. We forecast with our clients and monitor real-time data so we can store, ship, or adjust before any of that becomes a crisis. We partner with you to manage your inventory. ### The Return Ripple Effect Returns aren’t just about damaged products; they’re about damaged confidence. The moment a customer receives something broken, dented, or leaking, your packaging just became the villain. That’s why we engineer strength into every stage, from right-sized boxes to shock resistance, and why we pay as much attention to the [*unboxing experience*](https://www.ashtonne.com/blog/upgrade-your-unboxing-ashtonne-packaging) as the protection itself. ### The Supply Chain Domino One late delivery from a packaging supplier can halt production, delay shipments, or force you into costly rush orders. It’s why we built a network of dependable partners, emphasizing American-made materials wherever possible. It’s also why we ensure access to and experience with a variety of packaging materials.  To us, your [supply chain](https://www.ashtonne.com/supply-chain-solutions-for-your-fast-growing-ecommerce-startup) is critical to your business success. ![custom designed packaging on a pallet](https://www.ashtonne.com/hs-fs/hubfs/undefined-1.jpeg?width=260&height=195&name=undefined-1.jpeg) When you need a solution, you need it now, not when your packaging partner figures it out.  Consistency in supply equals reliability in business. We take both personally. ### The Unplanned Spike You’ve launched the campaign. Sales explode. The only thing that can’t keep up? Packaging. We’ve helped clients through those moments…from rush warehousing to  forecasting that anticipates the unexpected. Because growth is only good when your operations can grow with it and your suppliers understand it. ### Seeing What’s Coming Before It Comes The truth is, most packaging “disasters” don’t start as disasters. They start as small oversights like a missed reorder, bypassing a validation test, or a single late truck. What sets us apart at[ Ashtonne Packaging ](https://www.ashtonne.com/)is that we’ve seen enough of those moments to know what causes them, and we’ve built systems, relationships, and experience to make sure they don’t happen on our watch. Good packaging protects products. [Great packaging](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) protects reputations. Click [here ](https://www.ashtonne.com/customer-testimonials-of-packaging-partner)to read what our customers have to say. We’d love to talk with you about what is going great, and what issues might be lying in wait around the corner.  Even if you are happy and satisfied with your current packaging partner, it never hurts to get a second pair of eyes on things.  If you’d like to compare notes, we’re all in.  Give us a call at 877-522-6937 or [contact Ashtonne Packaging](https://www.ashtonne.com/surveys/cost-effective-retail-and-wholesale-packaging-designs) and let’s talk shop. We look forward to it. ## [![    Contact Us](https://no-cache.hubspot.com/cta/default/5108155/2cd96a44-0ce6-4705-b635-7aa158274279.png)](https://cta-redirect.hubspot.com/cta/redirect/5108155/2cd96a44-0ce6-4705-b635-7aa158274279) ** **Tags:** [custom designed packaging](https://www.ashtonne.com/blog/tag/custom-designed-packaging), [custom packaging](https://www.ashtonne.com/blog/tag/custom-packaging), [packaging company](https://www.ashtonne.com/blog/tag/packaging-company), [creative packaging](https://www.ashtonne.com/blog/tag/creative-packaging), [packaging partner](https://www.ashtonne.com/blog/tag/packaging-partner), [ecommerce packaging](https://www.ashtonne.com/blog/tag/ecommerce-packaging), [Brand packaging](https://www.ashtonne.com/blog/tag/brand-packaging), [brand merchandising](https://www.ashtonne.com/blog/tag/brand-merchandising), [merchandising](https://www.ashtonne.com/blog/tag/merchandising), [warehousing](https://www.ashtonne.com/blog/tag/warehousing), [trusted packaging partner](https://www.ashtonne.com/blog/tag/trusted-packaging-partner), [packaging pitfalls](https://www.ashtonne.com/blog/tag/packaging-pitfalls) [« Back to Blog](https://www.ashtonne.com/blog) #### Contact us using the form below or call us at [877-522-6937](tel:8775226937). ["Ashtonne Packaging has been our primary supplier of custom display products for several years. Their creative designers go above and beyond to quickly turn our ideas into physical samples, which helps ](https://www.ashtonne.com/customer-testimonials-of-packaging-partner)[Bendon](https://www.bendonpub.com) secure a great deal of promotional sales. Once we go to production, Ashtonne always delivers high-quality and eye-catching display solutions which allow our products to stand out from the competition at retail. I can sincerely say that Ashtonne’s overall service is the best I have experienced in the 8 years I have been a buyer of corrugated products!" [Rachel Rabalais](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Bendon](https://www.bendonpub.com) Ashland, Ohio [“We have been buying boxes and using Ashtonne Packaging for years now. The prices have stayed very competitive and the VMI service really works in our favor. They come once a week to do inventory and I am never out of boxes.”](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Mike Buckingham II](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Lake Erie Frozen Foods](http://www.leffco.net/) Ashland, Ohio ["The Ashtonne Packaging team has been instrumental in our business. The Ashtonne Packaging Team was able to work with our design team seamlessly from creating final drawings, artwork, and material selection, through production. We have continued to rely on them for other print and packaging needs."](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Josh Wiesman, Co-Founder and CEO](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Smilo Baby Products ](https://www.smilobaby.com) ["We talked to plenty of packaging people, and we tried to do that early on...I think we could go to a number of different companies that could deliver on budget and on time...But it was the level of detail and the craftmanship that you get at Ashtonne Packaging that I haven’t seen before.” ](https://www.smilobaby.com) [Keith Tritschler](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Smilo Baby Products](https://www.smilobaby.com) ["Ashtonne Packaging brought in several prototypes of a four-pack carrying carton for my approval… their designs met my specifications for functionality and attractive design… and they delivered on time, with quick turn-a-round!” ](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Doug Reynolds, Co-Founder and CEO](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Uniontown Brewing](https://www.uniontownbrewing.com) Ashland, OHIO [Working with Ashtonne Packaging was a dream. As a new business, we rely on business partners and vendors not just for their service, but for the experience and education they offer. Rich and the Ashtonne Packaging team were super knowledgeable, flexible, and patient. I also appreciated their willingness to work with low volumes (critical for new products) and that they have the capacity to handle so much more as we grow. They also provided some thoughts on our business outside of packaging showing that they were focused not just with their piece of the puzzle, but interested in supporting our all-around growth. And perhaps most importantly, our launch packaging was gorgeous and we get rave reviews from our customers on it! ](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Adiya Dixon, Founder](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Yubi Beauty](https://www.loveyubi.com) Powell, Ohio ["We continue to look for new ways to get in front of the consumer and are leveraging off-shelf displays more than ever before to achieve this objective. John Baxter and the team at ](https://www.ashtonne.com/customer-testimonials-of-packaging-partner)[Ashtonne Packaging](https://www.ashtonne.com) continue to deliver innovative display solutions that provide the flexibility and quality we need." [Tim McNamara, VP of Marketing- Perio, Inc](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Barbasol](https://www.barbasol.com) Ashland, Ohio ["We appreciate Ashtonne Packaging's keen packaging insights, and design expertise that have vastly improved our e-commerce packaging for both our own ecommerce business, and our Amazon business." ](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [John Domurad](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Lenox](https://www.lenox.com) ["I'm very happy with how smoothly the process went with Ashtonne Packaging. They are very helpful, the pricing is competitive, and the design team has been great."](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Mike Nash](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [SPX Brands](https://solarxeyewear.com/) [“Ashtonne Packaging worked with us for many months until we had the perfect packaging for our product. They went above and beyond every step of the way, and we are very happy with the final results. I’d highly recommend them, especially for those looking for quality packaging Made in the USA.” ](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Michael C. Rice, Inventor/Founder/Co-CEO ](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Gripknife LLC](https://www.gripknife.com) [“Before we installed the automation equipment from Ashtonne Packaging, we would need twenty to twenty-five employees to produce about 2,000 packages. On typical days, six workers would produce 750 units . Now just four employees can produce 800 units. It has completely exceeded our expectations.”](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Eric Wentworth](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Fin Fur Feather Outfitters](https://www.finfeatherfur.com) ["I want you to know that I receive amazing feedback daily, from customers and fellow business owners, on the quality and style of your packaging. You knocked our packaging out of the park and I am truly grateful. You will be hearing from me soon with another order. Until then, keep doing great things!"](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Heather Chabino, Co-Owner](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Hob Nob Candles](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) ["Regarding the Skullmate Hanger Project, we and our client have been thrilled with how it turned out and how it functions". ](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Emily Miller, Owner](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Inspire Design](https://www.inspiredesignco.com) [“We talked to plenty of packaging people, and we tried to do that early on...I think we could go to a number of different companies that could deliver on budget and on time… But it was the level of detail and the craftsmanship that you get at Ashtonne Packaging that I haven’t seen before.” ](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Keith Tritschler](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Smilo Baby Products](https://www.smilo.com) [" Thank you for being such a dependable supplier to us. It's nice not to have people I don't have to worry about". ](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [J. Howard](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [J-Lenco, Inc](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) ["We can tell you that the first batch that was sent to REI sold out around Thanksgiving, good and bad problem. The distributor has sent a second batch to REI and we are waiting for the product to activate on the site again. It was cool walking into our local store and seeing the product on the shelves/peg board".](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Brad Kenemuth](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [The Liftie](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Regarding the Tasting Board Retail Kit Project, Matt Snyder said: "Whoa! Mind blown! That is incredible! I love it! Cheers!"](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Matt Snyder](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Founder](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) ["As a consumer-facing brand, we really value a customer's first impression of our product in-store. When we expanded into a larger retailer, we looked to Ashtonne for help designing a custom display to showcase our alcohol infusion kits. The team at Ashtonne listened to our needs and quickly came up with a creative way to show our products. Everyone we worked with at Ashtonne was flexible and offered solutions for pricing that worked within our budget. As a result of using the display stands, our product is selling faster than accounts that do not have a display case!"](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [John Feller, co-Founder](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) [Aged and Infused](https://www.ashtonne.com/customer-testimonials-of-packaging-partner) ![Ashtonne Packaging](https://www.ashtonne.com/hs-fs/hubfs/Ashtonne_Packaging_December2018/images/ashtonne_logo_white.png?width=328&height=112&name=ashtonne_logo_white.png) 1235 Jacobson Ave, Ashland, OH, 44805 Toll-Free: [877-522-6937](tel:877-522-6937) Fax: [877-292-5660](tel:877-292-5660) Follow Us: [![Linkedin](https://www.ashtonne.com/hs-fs/hubfs/Ashtonne_Packaging_December2018/images/linkedin-512.png?width=50&height=50&name=linkedin-512.png)      ](https://www.linkedin.com/company/11170776)  [![Facebook](https://www.ashtonne.com/hs-fs/hubfs/Ashtonne_Packaging_December2018/images/fb-f-logo__blue_100.png?width=50&height=50&name=fb-f-logo__blue_100.png)      ](https://www.facebook.com/AshtonnePackaging/) [![Twitter](https://www.ashtonne.com/hs-fs/hubfs/Ashtonne_Packaging_December2018/images/twitter_logo_transparent.png?width=55&height=55&name=twitter_logo_transparent.png)](https://twitter.com/Ashtonne_pkg)      [![Youtube](https://www.ashtonne.com/hs-fs/hubfs/Ashtonne_Packaging_December2018/images/youtube_2.png?width=55&height=55&name=youtube_2.png)](https://www.youtube.com/playlist?list=PLvH14R6_JrMsTINzuWseni4dUfcHsJezO)      [![Pinterest](https://www.ashtonne.com/hs-fs/hubfs/pinterest-logo%202.png?width=89&name=pinterest-logo%202.png)](https://www.pinterest.com/ashtonne8775226937/)[![Instagram hi-res](https://www.ashtonne.com/hs-fs/hubfs/Instagram%20hi-res.png?width=93&name=Instagram%20hi-res.png)](https://www.instagram.com/ashtonnepackaging/) Digital Marketing Powered by Bryan Media and Bill Madl [![blue-seal-200-42-bbb-235829533 copy](https://www.ashtonne.com/hs-fs/hubfs/blue-seal-200-42-bbb-235829533%20copy.png?width=200&height=42&name=blue-seal-200-42-bbb-235829533%20copy.png)](https://www.bbb.org/us/oh/ashland/profile/packaging-design-and-development/ashtonne-packaging-inc-0272-235829533/#sealclick)   Copyright © 2018 Ashtonne Packaging. 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