How to choose the right corrugated box size in India
Measure your product at its widest points, add 0.25 inch per side for a snug fit (or 0.5–1 inch if you use void fill), then pick the smallest PackWorks stock size that still closes cleanly — a box that is 2 inches too big on each side can double the courier’s volumetric charge.
Updated 5 Sept 2026 · PackWorks By Velun, Karnal
Step 1 — Measure the product, not the old box
Use a tape on the product (or the product in its retail carton) at the widest points. Write length, width and height in inches — that is how Indian corrugated dies are specified. Convert centimetres by dividing by 2.54.
Step 2 — Add packing allowance
A snug apparel or book fit needs about 0.25 inch per side. Bubble wrap, kraft paper or an insert needs 0.5–1 inch. Never force a product into a box that is smaller than the product — flaps will bow and the courier will refuse or crush the parcel.
Step 3 — Understand volumetric weight
Delhivery, Blue Dart, DTDC and most Indian surface couriers charge the greater of actual weight and volumetric weight. The common formula is length × width × height in centimetres, divided by 5,000. Air cargo sometimes uses 6,000. A 12 × 10 × 8 inch box is about 30.5 × 25.4 × 20.3 cm — volumetric weight ≈ 3.1 kg even if the contents weigh 400 g.
Inner vs outer dimensions
Every PackWorks size is an inner dimension. Outer size is roughly 0.25 inch larger per side on 3-ply and 0.5 inch on 5-ply. Couriers measure the outer carton, so a tight inner fit still wins on volumetric billing.
Use the size finder
Enter L, W and H on packworks.velun.in/size-finder. We rotate the item on the base and rank every stock size by unused volume, with pack price shown. If nothing fits, the largest stock carton is 24 × 18 × 18 inch; custom sizes start at 500 pieces.