“Pick, pack and post” is how most small Australian businesses describe their own dispatch: pull the order, pack it, and lodge it with Australia Post. It works well at low volume. The cost and the effort creep up quietly as you grow, and almost always in the same two places, the packaging format and the postage band it lands in. This guide covers how to run pick, pack and post efficiently, how to keep parcels in the cheapest post bands, and when to move beyond the Post Office counter.
What “pick, pack and post” involves
- Pick. Collect the items in the order from wherever stock is kept.
- Pack. Check the items, protect them if needed, and seal them into a satchel or box.
- Post. Weigh and measure the parcel, buy the right postage, and lodge it, at a Post Office, a street posting box for small satchels, or through a business pickup.
It is the same core sequence as any warehouse pick and pack process, just at a scale where one person often does all three steps.
The postage band is where the cost is decided
Australia Post parcel pricing steps up by size and weight band. A parcel that is slightly too big or slightly too heavy for a band pays the next band up, which can be a large jump for a small increase in size. Two habits keep costs down:
- Use flat-rate satchels where they suit. Prepaid satchels are a fixed price up to a weight limit regardless of destination, which is predictable and often cheaper for anything that fits.
- Right-size everything else. For your own packaging, measure the packed parcel and choose the smallest satchel or box that holds it. Cubic sizing applies to larger and lighter parcels, so a half-empty box can be charged well above its actual weight.
More on this in where pick and pack fees come from.
Packaging for pick, pack and post
| Order type | Format |
|---|---|
| Flat, soft, non-fragile (apparel, textiles, prints) | Right-sized poly satchel or kraft paper mailer |
| Small and a bit fragile (cosmetics, ceramics, electronics accessories) | Recyclable honeycomb padded mailer |
| Multi-item or rigid goods | Right-sized mailing box with paper void fill and water activated tape |
| Heavier or higher value | Double-wall box, reinforced tape, edge protection |
A practical small-business kit is two satchel sizes, one padded size and two box sizes. Keep them pre-opened at your packing spot so posting an order is a one-minute job.
Running the bench efficiently at small scale
- Batch your picks. Collect the day’s orders in one pass rather than walking to the shelf for each.
- Print labels in a batch. Buy postage for all orders at once through a Post business account or a shipping app, so lodgement is a single drop-off.
- Stage packaging. Satchels and boxes open and within reach, tape in a dispenser.
- Weigh as you go. A small bench scale so you buy the right band first time and avoid counter surprises.
- Book a pickup once volume justifies it. A daily parcel pickup removes the trip to the Post Office entirely.
When to move beyond Australia Post
Post is hard to beat for light satchels and low volume. Consider adding a courier account when:
- You regularly ship parcels over about 3 to 5 kg, where courier rates often beat parcel post.
- You have the volume to negotiate a rate, usually a few hundred parcels a month.
- You need guaranteed next-day or same-day service.
Many businesses keep both: Post for small satchels, a courier for bulky or heavy orders. See pick and pack for couriers.
Do you need to outsource?
At the point where pick, pack and post eats too much of your week, the instinct is to hand it to a fulfilment provider. Sometimes that is right. Often, tightening the packaging range and batching the workflow buys back most of the time for a fraction of the cost. Work through contract packing versus smart in-house packaging first. If you do outsource, you still choose the packaging spec.
How Carewell Group helps
Carewell Group is an Australian packaging manufacturer and supplier. For pick, pack and post we provide:
- Poly satchels, kraft paper mailers and recyclable honeycomb padded mailers sized to keep parcels in the cheapest post bands.
- Right-sized mailing boxes, paper void fill and water activated tape.
- Custom print on mailers and tape so small-run orders still look considered.
- Sizing advice: send a week of parcel dimensions and we will recommend the formats that cut your postage.
Carewell can meet all your packaging needs for your business. Talk to our expert and we will work to your required MOQ. Call +61 (02) 8760 1491 or request samples and a sizing review.
Frequently asked questions
What does “pick, pack and post” mean?
Picking a customer order, packing it into a satchel or box, then weighing it and lodging it with Australia Post. It is how most small businesses handle their own dispatch.
How do I reduce postage costs?
Use flat-rate prepaid satchels where items fit, right-size your own boxes so cubic sizing does not inflate the charge, and weigh parcels before buying postage so you land in the correct band.
When should I switch from Australia Post to a courier?
When you regularly ship parcels over about 3 to 5 kg, or have the volume (a few hundred a month) to negotiate a courier rate, or need guaranteed next-day service.
Do I need a fulfilment provider?
Not necessarily. Tightening your packaging range and batching picks and label printing recovers most of the time at a fraction of the cost. Review the in-house versus contract comparison first.
Sources
- Australia Post, parcel post and prepaid satchels: auspost.com.au
- Australia Post, cubic weight and parcel sizing: auspost.com.au
Written by Alif Vasaya, digital and content strategy, Carewell Group. Carewell Group is an Australian packaging, food packaging, tape, industrial safety and 3PL supplier serving all of Australia. Last updated 10 September 2026.