Free shipping promotions are effective at driving conversions, but when a customer orders heavy products on a low-value basket, the actual shipping cost can exceed the margin on the sale. Without a flag, these unprofitable orders are fulfilled automatically and the loss is only visible in monthly reporting.
OrderBadger can flag orders where free shipping on a heavy, low-value basket is likely costing you more than the profit on the sale.
Stores selling heavy products - hardware, pet food, beverages, gardening supplies - that offer free shipping thresholds and want to catch orders where the promotion actually costs money.
How it works
Checks three conditions: the order must have free shipping (zero shipping cost), the total weight must exceed 8 kg, and the subtotal must be under £50. When all three are true, the order is badged as a margin squeeze and appears in your inbox for review.
Review whether your free shipping threshold is set correctly. Consider raising the minimum basket value for free shipping, or adding a weight surcharge for heavy items. For this specific order, decide whether to absorb the loss for customer goodwill or contact the customer about shipping options.
Rule template
Write this (or something similar) in the OrderBadger rule builder. The AI compiler turns it into executable logic automatically.
Make it yours
- Lower 'over 8 kg' to 'over 5 kg' if your carrier charges steeply for parcels above 5 kg, making lighter orders also a margin concern.
- Raise 'less than £50' to 'less than £75' if your product margins are thin and even mid-value baskets lose money on heavy free shipping.
- Tighten 'over 8 kg' to 'over 15 kg' to focus only on the heaviest parcels where carrier surcharges are most significant.
- Add 'and shipping is international' to catch heavy free-shipping orders crossing borders, where delivery costs are highest. …otal order weight is over 8 kg and subtotal is less than £50 and shipping is international
- Add 'and customer has 3 or more previous paid orders' to see whether loyal customers are routinely exploiting your free shipping policy on heavy items. …otal order weight is over 8 kg and subtotal is less than £50 and customer has 3 or more previous paid orders
Badge preview
When this rule matches
When this rule does not match
Workflow
This rule includes workflow features that help your team act on flagged orders.
Good to know
- Weight calculation depends on product weights being correctly set in WooCommerce. Missing weights mean the total may be underestimated and some heavy orders will slip through.
- The subtotal threshold is in your store's default currency. Adjust the rule text for your price range.
- This does not calculate the actual shipping cost - it flags likely unprofitable combinations based on weight and basket value.
Frequently asked questions
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Why does the rule check subtotal instead of total?Subtotal reflects the product value before shipping and tax. Since shipping is free, total and subtotal may be similar, but subtotal gives a clearer picture of the actual merchandise value being shipped.
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Does an order weighing exactly 8 kg trigger the badge?No. The rule requires more than 8 kg. An order at exactly 8.0 kg will not be flagged. Adjust the threshold in the rule text if you want to include the boundary.
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Can I use this to automatically add a shipping surcharge?OrderBadger is informational - it does not modify order totals. Use the badge as a trigger for your team to review shipping policy, or configure WooCommerce shipping rules to prevent the scenario in the first place.
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What if I offer free shipping over a certain basket value but the threshold is below £50?You may see many orders triggering this rule. Consider raising your free shipping threshold in WooCommerce so that heavy low-value baskets no longer qualify for free delivery.
Related rules
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