Packaging Best Practice: How to Avoid Australia Post Delays (Lessons from Inside a Sorting Facility)

When it comes to shipping, most online sellers focus on speed after dispatch—but what happens inside an Australia Post sorting facility can make or break your delivery times.

After visiting an AusPost sorting centre, we saw firsthand how parcels move through automated systems—and more importantly, what causes delays.

If you want faster delivery and fewer issues, these packaging best practices will make a real difference.

Why packaging best practice matters

Australia Post facilities rely heavily on automated scanning and conveyor systems. When parcels can’t be processed automatically, they’re pulled out for manual handling—slowing everything down.

The goal is simple: make your parcel easy for machines to read and move.

1. Protect the QR code and barcode

AusPost scanners rely heavily on the QR code. They contain key shipment data (including dimensions and if it fails, the entire process slows down

AusPost scanners read the QR code first, then the barcode.

• Don’t crease, smudge, or cover either code

• Avoid placing labels where they can bend or distort

• Ensure high print quality and clarity

If scanners can’t read the label instantly, the parcel gets rejected for manual processing.

2. Never tape over the label

This is one of the most common mistakes. Tape creates glare and reflection and makes labels harder for scanners to read. Damaged readability = delays

Best practice: Use tape to seal the box, not to cover the label.

3. Place labels on the largest flat surface

Flat surfaces are critical for smooth processing.

• Parcels move quickly along conveyor belts

• Flat placement ensures scanners can detect and read labels easily

• Curved or uneven surfaces increase failure rates

If the label isn’t easy to “see,” the system struggles.

4. Avoid plastic label pockets

While they might seem protective, they actually cause issues.

• Plastic reflects light

• Can distort the barcode/QR code

• Slows down scanning accuracy

  
  

Use plastic pockets for International orders where additional customs details are required. For domestic orders, they’re unnecessary best to stick the label directly on the parcel.

5. Be careful with box joins

Placing labels over seams or joins is risky.

Boxes flex during transit causing labels to tear, crease, or distort. This can make them unreadable mid-process. Always place labels on a solid, uninterrupted surface.

6. Keep parcels flat (avoid round shapes)

Shape matters more than you think. Round or uneven parcels can roll on conveyor belts, get stuck, may fall off and require manual recovery. This adds delays and handling time

Best practice: Pack items so the parcel maintains a stable, flat shape.

7. Consider Your Packaging Colour

Black packaging isn’t rejected, but it’s not ideal. It blends into conveyor belts and makes detection harder for scanning systems. If possible, use lighter packaging or ensure strong label contrast.

8. Leave Clear Space for Labels

For branded packaging:

• Avoid placing labels over busy designs

• Use a clear, defined label area

• This helps machines quickly identify the label zone

  
  

Think of it like giving the scanner a clean target.

Final Thoughts

Good packaging isn’t just about protection—it’s about efficiency through automation.

By following these packaging best practices, you can:

• Reduce sorting delays

• Avoid manual processing

• Improve delivery speed

• Create a better customer experience

For more detailed guidelines, you can also refer to the official Australia Post Freight Preparation Guide.