Packaging Guidelines: Parcel Carriers Packaging Requirements

For small to medium-sized businesses that rely on packaging, shipping, and warehouse services, understanding the specific requirements of various parcel carriers is crucial for ensuring safe and efficient delivery of goods.

Proper packaging is not only crucial for your products to reach their destination safely, but to also arrive without delays and damage claims.

Let’s look at the most common parcel carriers for both U.S. and international shipments and their specific packaging requirements.

U.S. Parcel Carriers

United States Postal Service (USPS)

The U.S. Postal Service (USPS) provides mail processing and delivery services to individuals and businesses in the U.S. The USPS was established in 1775, by the Second Continental Congress with Benjamin Franklin as the first Postmaster General. The USPS handled 116.15 billion units of mail in 2023, a steep decline from 213 billion units in 2006.

• Packaging materials: Corrugated boxes, cushioning materials, and strong tape.
• Labeling: Clear and legible shipping labels with complete sender and recipient information.
• Prohibited contents: Hazardous materials, flammable items, and restricted substances.
• USPS specifics:
  •  Step 1 Can I Send This? The maximum weight for a USPS package is 70 pounds. Also, there are some things that you can’t send at all (prohibited) and other things you can only send under certain conditions (restricted). Hazardous materials (HAZMAT) might be prohibited or restricted. As a rule of thumb, if what you’re sending could harm people or cause damage (like lithium batteries), very carefully check the list of Domestic Shipping Prohibitions, Restrictions, & HAZMAT.
    
    
  • Step 2 Choose a Shipping Service: Options include Priority Mail Express (next day or 2-day); Priority Mail (1 to 3 business days); USPS Ground Advantage (2 to 5 business days); and Media Mail (only books or educational materials).
    
    
  • Step 3 Pick and Prepare Your Packaging: Whether you’re using a box, padded envelope, or tube, use packaging that doesn't bulge and is strong enough to protect what you’re sending. And accurately measure the size and weight of your package so you can avoid unexpected fees.
    
    
  • Step 4 Address Your Package: Please write the address parallel to the longest side of the package, and make sure your return address, the delivery address, and postage will fit on the same side. If you'll be printing a shipping label (with postage included), you can use that instead of a separate address label.
    
    
  • Step 5 Calculate Postage and Add Insurance or Extra Services: You can pay for postage at a Post Office; use stamps (you might need a lot); or in many cases, even buy postage online at (and print it yourself) using Click-N-Ship® service.
    
    
  • Step 6 Ship Your Package: If your package uses stamps and is more than one-half inch thick or weighs more than 10 oz, you must take it to a Post Office counter and give it to the Retail Associate at the counter. If you printed the postage using Click-N-Ship or at a USPS kiosk, you can use any method to drop off your packages.

United Parcel Service (UPS)

United Parcel Service, Inc. (UPS), is an American multinational shipping and receiving and supply chain management company founded in 1907. Originally known as the American Messenger Company specializing in telegraphs, UPS has grown to become a Fortune 500 company and one of the world’s largest shipping couriers.

• Packaging materials: Corrugated boxes, pressure-sensitive plastic tape, and cushioning materials.
• Labeling: UPS shipping labels with sender and recipient information, and any necessary handling labels.
• Prohibited contents: Hazardous materials, illegal items, and packages exceeding size and weight limits. Refer to ups.com/hazmat.
• UPS specifics:
  • To prepare packages for UPS shipment, you can use your own packaging if boxes are new or almost new, or one of a variety of containers provided free of charge that can be used with certain, selected UPS services. Customers with a UPS account can request supplies at Packaging and Shipping Supplies UPS - United States or by calling 1-800-PICK-UPS®.
    
    
  • Goods that are susceptible to damage from normal handling or to exposure to dirt, water, scratches, or marks, should be placed in a protective outer box.
    
    
  • Types of packaging cushioning materials include Air-Encapsulated Plastic (cell bubble sheeting), Inflatable Packaging (airbags), Expanded Polystyrene “Peanuts” (loose fill), Engineered foam closures, corrugated liners, and inserts, and crumpled Kraft paper.
    
    
  • For small package shipments: Ship freight in corrugated boxes (avoid reusing boxes), crates, or shipping containers. Use a container strong enough to support the weight of the contents. Use at least two inches of appropriate cushioning materials. Reinforce edges to protect from bending. Securely seal closures and seams with reinforced tape. Do not use masking, cellophane, duct, or water-activated paper tapes. Label each piece with telephone numbers and complete address information, including postal code of the shipper and consignee.

FedEx

FedEx Corporation (formerly Federal Express Corporation and FDX Corporation) is an American multinational conglomerate holding company focused on transportation, e-commerce, and business services based in Memphis, Tennessee. FedEx is the fifth largest American-headquartered employer globally with 547,000 employees.

• Packaging materials: Corrugated boxes, cushioning materials, and pressure-sensitive adhesive tape.
• Labeling: FedEx shipping labels with sender and recipient information, and any necessary handling labels.
• Prohibited contents: Hazardous materials, illegal items, and packages exceeding size and weight limits.
• FedEx specifics:
  • You may use your own packaging if the boxes are sturdy and undamaged with all flaps intact. Chipboard boxes, such as gift or shoe boxes, must be packed into a corrugated fiberboard outer box. Use double-wall boxes for heavier items.
    
    
  • Ensure your package is fully encased in an outer shipping container or packaging. The outer container should be made of corrugated fiberboard materials.
    
    
  • Wrap items individually with cushioning material and center them in boxes away from other items and away from the sides, corners, top, and bottom of the box.
    
    
  • Position bottles that contain liquids upright. Use an inner seal and perforated breakaway cap. The inner packaging must be able to contain leaks.
    
    
  • Place items that might be damaged by normal handling, such as soiling, marking, or application of adhesive labels, in a protective outer box.
    
    
  • For odd- or irregular-shaped items, at a minimum you should wrap and tape all sharp edges or protrusions.
    
    
  • Enclose an extra label, business card, or letterhead with the shipper’s address and phone number and the recipient’s address and phone number inside the package before sealing it.
    
    
  • Remove all old address labels from reused boxes before shipping, and make sure there are no holes, tears, or corner dents in the outer box.
    
    
  • Use fillers like crumpled newspaper, loose-fill peanuts, or air-cellular cushioning material such as Bubble Wrap® to fill void spaces and prevent movement of goods inside the box during shipping.
    
    
  • Use the H-taping method for sealing your package.
    
    
  • Use pressure-sensitive plastic tape, water-activated paper tape (minimum 60-lb. grade), or water-activated reinforced tape that is at least 2" wide.
    
    
  • Do not use cellophane tape, duct tape, masking tape, string, or rope to seal packages. In addition, do not wrap the outer box in shrink wrap, stretch wrap, or Bubble Wrap.
    
    
  • Place delivery information inside and outside the package. Include an address for your recipient and yourself. Remove or cross out any old address labels on the outer box.
    
    
  • Shipping labels and packing slips should be applied facing the same direction on the same side of the package.

International Parcel Carriers

DHL Express

DHL Express is a German logistics company providing courier, package delivery, and express mail service, delivering over 1.7 billion parcels per year. The company can trace its founding to San Francisco in 1969 but was acquired by German interests by 2002.

• Packaging materials: Corrugated boxes, cushioning materials, and pressure-sensitive adhesive tape.
• Labeling: DHL waybills with sender and recipient information, and any necessary customs documentation.
• Prohibited contents: Hazardous materials, illegal items, and packages exceeding size and weight limits.
• DHL specifics:
  • Step 1 Assess: Consider the weight and fragility of contents; value of content being shipped; and packing requirements prescribed by transportation regulations.
    
    
  • Step 2 Pack: Use quality double wall boxes. Ensure 6 centimeters of distance between shipment contents and all walls of the box. Fill all void space.
    
    
  • Step 3 Seal: Use pressure-sensitive tape of at least 48 mm width. Use the H-taping method to seal all edges and seams.
    
    
  • Step 4 Label: Apply the shipment label to the top surface of your package – clearly displayed on a single surface.
    
    
  • Other Considerations: Special packaging materials and packing techniques are required for shipping liquids and powders.
    
    
  • Always use high-quality corrugated cardboard boxes for parcels. For fragile or heavy items, double-wall or tri-wall constructions are recommended. Avoid reusing old boxes as they may have lost some of their rigidity.
    
    
  • Bubble wrap, airbags, cardboard, and foam peanuts/pellets are all commonly used as packaging material. All have different qualities, and it is important to use them appropriately.
    
    
  • Leave no empty space! It is important to completely fill empty space within the box to avoid contents moving during transit which can cause damage to both the contents and box.

UPS Worldwide Express

UPS Worldwide Express is a shipping service that offers guaranteed morning delivery within three business days for international shipments. It is one of UPS’s faster international shipping options, with deliveries taking an average of 1 to 3 business days to reach their destination.

• Packaging materials: Corrugated boxes, pressure-sensitive plastic tape, and cushioning materials.
• Labeling: UPS shipping labels with sender and recipient information, and any necessary handling and customs labels.
• Prohibited contents: Hazardous materials, illegal items, and packages exceeding size and weight limits.
  · See above for specific requirements.

FedEx International

FedEx International offers next-flight options as well as 1 to 5-day global shipping economy, priority, and priority express shipping. With FedEx International Connect Plus you can ship to 198 countries and territories in 2 to 5 days.

• Packaging materials: Corrugated boxes, cushioning materials, and pressure-sensitive adhesive tape.
• Labeling: FedEx shipping labels with sender and recipient information, and any necessary handling and customs labels
• Prohibited contents: Hazardous materials, illegal items, and packages exceeding size and weight limits.
  ·See above for specific requirements.

General Packaging Guidelines

No matter what parcel carrier you select, here are some general packaging guidelines for your shipment:

• Use sturdy, corrugated boxes suitable for the weight and size of the contents.
• Ensure proper cushioning and void fill to prevent damage during transit.
• Use strong, pressure-sensitive adhesive tape to seal packages.
• Label packages clearly with complete sender and recipient information.
• Include a packing slip with a detailed list of contents for easier custom clearance (international shipments).
• Include any necessary handling labels (e.g., "Fragile," "This End Up").
• Adhere to size and weight restrictions set by each carrier.
• Avoid shipping prohibited items, such as hazardous materials and illegal substances. Each carrier maintains a list of prohibited items. Common examples include flammable liquids, aerosols, and perishables. Check the carrier's website for their specific list.
• Distribute weight evenly within the box to prevent damage.
• Blunt any sharp edges on products to prevent box punctures.

By following the specific packaging requirements of the most common U.S. and international parcel carriers, small to medium-sized businesses can ensure their packages are delivered safely and efficiently.

Always use appropriate materials, label packages clearly, and adhere to any size, weight, and content restrictions to avoid delays or returned shipments.

Contact Performance Packaging today for a partner in getting your packages delivered safely, accurately and on-time.