How to Safely Pack Items for International Shipping

Sending a parcel overseas? Your packaging has an important job to do.

Whether you're an ecommerce business sending orders to customers abroad or simply need to ship a product internationally, your parcel could travel hundreds – or thousands – of miles before reaching its destination.

Along the way, it may be moved between vehicles, sorting facilities, depots and different delivery networks.

That makes choosing the right packaging particularly important.

A cardboard box that's too large can allow the product to move around.

A box that's too small might not leave enough room for protection.

And a box that isn't strong enough could become damaged during transportation.

So, how should you safely pack something for international shipping?

Here's where we'd start.

1. Choose the right size cardboard box

It can be tempting to start with whatever cardboard box you already have available.

If the product fits inside, what's the problem?

Potentially quite a lot of empty space.

Imagine you're sending a product measuring:

300mm × 200mm × 100mm

but the closest stock box you have is:

450mm × 350mm × 250mm

The product fits.

But you're now shipping a considerable amount of empty space alongside it.

You'll need to fill that space to prevent the product moving around during transportation.

A better starting point is a box closer to the dimensions your product actually requires.

Don't choose the biggest box your product fits inside. Choose the smallest appropriate box that allows enough room for the protection it needs.

2. Leave enough room for protective packaging

Right-sized doesn't mean tight-sized.

This is particularly important when you're shipping fragile products internationally.

If you're sending something delicate, don't make the cardboard box exactly the same dimensions as the product.

You need enough space around it for appropriate protective material.

How much protection you require will depend on what you're sending.

A robust product might require relatively little.

Glassware, ceramics, electronics and other fragile items may require considerably more.

The aim is to find the balance.

Enough space for appropriate protection – without creating unnecessary empty space.

3. Choose the right strength of cardboard

Size isn't the only consideration.

The strength of your cardboard box matters too.

At ASC Direct, we manufacture boxes using different grades of corrugated cardboard, including Single Wall, Double Wall and Heavy Duty options.

Which one should you choose?

It depends on what you're sending.

The weight of the product, its shape, how fragile it is and how much protection it requires should all be considered.

A lightweight, robust product might be perfectly suitable for a Single Wall box.

For heavier, more fragile or higher-value products, a stronger board grade may be more appropriate.

International shipping can involve a long journey and multiple stages of handling, so this isn't somewhere we'd recommend choosing a weaker box simply to save a small amount on the packaging.

The cardboard box needs to be suitable for what's inside it.

4. Stop the product moving inside the box

Once you've chosen the box, there's a simple test you can perform.

Pack the product as you intend to send it.

Close the box.

Then gently move it.

Can you feel the product moving around inside?

If you can, you may need additional protection.

Products that move around inside their packaging can repeatedly hit the sides of the box as the parcel is transported.

Appropriate cushioning and void fill can help hold the item securely in position.

But there's an important distinction here.

Use protective packaging because your product needs protecting – not simply because your box is unnecessarily large.

Starting with a right-sized box can reduce the amount of empty space you need to deal with in the first place.

5. Protect fragile items individually

Sending several products in the same box?

Don't only protect the outside of the group.

Think about how the individual products could interact during transportation.

Two fragile products packed next to one another could knock together inside the box.

Wrap delicate items individually where appropriate and consider using protective material between them.

The objective is to protect products from both:

The outside world and each other.

Pay particular attention to corners, edges and protruding parts that could be vulnerable to knocks or could damage other items inside the parcel.

6. Don't rely on a 'FRAGILE' label

There's nothing wrong with adding a FRAGILE label when appropriate.

But it shouldn't be your primary method of protecting the product.

Your parcel still needs to be packed so that it can withstand the normal handling associated with a parcel delivery network.

Labels can provide useful handling information.

Good packaging provides the protection.

If an item would be damaged without special treatment throughout its entire journey, reconsider whether the packaging itself is sufficient.

7. Consider a box within a box for particularly fragile items

For particularly fragile or valuable products, you may want to consider double boxing.

This involves packing and protecting the product inside one box before placing that box inside a larger outer box with additional cushioning between the two.

The outer box provides another layer of protection against impacts.

It isn't necessary for every international shipment.

In fact, for many products it would simply create unnecessary packaging.

But for particularly delicate items, double boxing can provide useful additional protection.

Always check the packaging requirements of your chosen courier, particularly when shipping valuable or specialist goods.

8. Pay attention to corners and empty spaces

When adding protective material, don't just put some on top of the product and close the box.

Look at the parcel as a whole.

Could the product move from side to side?

Could it move upwards?

Are there vulnerable corners?

Could two products collide?

Fill the areas that need protection so the contents remain appropriately secured.

Materials such as HexcelWrap® can provide a paper-based protective wrapping option for suitable products.

Other products may require different forms of cushioning or specialist protective packaging.

There's no single packaging solution that's right for everything.

Package according to the product you're actually sending.

9. Seal the box properly

You've chosen the right box.

You've protected the product.

Don't make the sealing of the parcel an afterthought.

Use packaging tape suitable for the weight and construction of the box and make sure the main openings are securely sealed.

Pay particular attention to the joins and flaps of the box.

For many everyday parcels, paper packaging tape can provide an alternative to conventional plastic packaging tape while helping you create a predominantly paper and cardboard-based packaging solution.

For particularly heavy parcels, however, make sure whatever tape and sealing method you choose is appropriate for the weight and journey involved.

The best cardboard box in the world isn't much use if it opens during transportation.

10. Remove old labels if you're reusing a box

Reusing cardboard boxes can be a practical way to extend their useful life.

But inspect them carefully first.

Is the cardboard still strong?

Has the box become crushed?

Has it been exposed to water or damp?

Are the corners damaged?

And importantly:

Are there any old delivery labels or barcodes still attached?

Remove or completely cover previous shipping labels and barcodes before sending the parcel.

You don't want old delivery information creating confusion during sorting.

If the box has lost its structural strength, use another one.

Reusing packaging makes sense only when the packaging remains suitable for the job.

11. Think about moisture

An international parcel can experience very different conditions during its journey.

Depending on the destination and shipping method, changes in temperature and humidity may be another consideration.

Corrugated cardboard is paper-based, so excessive moisture can affect its performance.

If the contents are particularly sensitive to moisture, consider whether they require additional internal protection.

Again, this should be based on the product and journey rather than simply adding additional packaging to every parcel.

12. Check your courier's international packaging requirements

There isn't one universal set of packaging rules covering every international shipment.

Different couriers, destinations and products can have different requirements.

Before sending your parcel, check the latest guidance from the courier you're actually using.

This is particularly important if you're sending:

• Batteries

• Liquids

• Aerosols

• Perfumes

• Food

• Alcohol

• Medicines

• Chemicals

• High-value items

• Perishable products

Some goods can be restricted or prohibited entirely, while others may require specific packaging, labelling or documentation.

Never assume that because you can send something within the UK, you can automatically send it internationally.

13. Don't forget customs documentation

Packaging protects what's inside the parcel.

But getting an international shipment to its destination can also require the correct customs information.

Depending on where you're sending the goods, you may need to provide information about the contents, value, country of origin and appropriate commodity codes.

Your courier or shipping provider should explain the documentation required for your particular service and destination.

Make sure any required documentation and labels are attached in the location and format specified by your carrier.

Incorrect or incomplete information could delay your parcel regardless of how well you've packed it.

Could a smaller box reduce international shipping costs?

Potentially.

Many parcel carriers take both weight and parcel dimensions into consideration when calculating charges for certain services.

That means an unnecessarily large box isn't necessarily just using more cardboard and void fill.

It could potentially affect your shipping costs too.

Imagine sending hundreds of parcels internationally each year in boxes significantly larger than the products inside them.

You're potentially:

Using more cardboard.

Using more void fill.

Taking up more storage space.

And transporting more volume than necessary.

This is another reason to consider the finished parcel, rather than simply the price of the empty cardboard box.

Always check the pricing rules for your chosen courier and service, as charging methods vary.

Stock box or custom-sized box?

There's nothing wrong with using a stock cardboard box for international shipping.

In fact, if you can find a stock box that's the right size and strength for your product, it can be an extremely cost-effective option.

Mass-produced stock boxes are often cheaper than boxes manufactured specifically to your dimensions.

But what happens when the closest stock size isn't particularly close?

You could accept the oversized box and fill the remaining space with additional packaging.

Or you could start with a box manufactured closer to the dimensions you actually require.

The question isn't simply:

"Which box is cheapest?"

It's:

"Which packaging solution is right for the complete shipment?"

Consider the box, protective packaging, packing time, storage requirements, product protection and potential impact of parcel dimensions on shipping charges.

Custom-sized shipping boxes from just 25 boxes

You don't need to be shipping thousands of international orders to use custom packaging.

ASC Direct manufactures custom-sized corrugated cardboard boxes from quantities as low as 25 boxes.

Using our online Box Builder, you can specify the internal:

Length × Width × Depth

you require.

You can then choose your cardboard grade, quantity and other options before getting an instant price online.

This can be particularly useful if you regularly send the same products internationally and find yourself repeatedly using an oversized stock box.

Instead of making the product fit the box:

Make the box fit the product.

A simple international packing checklist

Before sending your next international parcel, ask yourself:

• Is the box the right size for the product?

• Is the cardboard strong enough?

• Is there enough room for appropriate protection?

• Is unnecessary empty space kept to a minimum?

• Can the product move inside the box?

• Are multiple fragile products protected from each other?

• Is the box securely sealed?

• Are the shipping labels clear?

• Have old labels and barcodes been removed?

• Have you checked your courier's latest packaging requirements?

• Is the product permitted for the destination?

• Have you completed the required customs information?

If you can answer those questions confidently, you're giving your parcel a much better start to its journey.

The longer the journey, the more important the packaging

You can't control everything that happens to a parcel after it leaves you.

But you can control how it starts its journey.

Choose a box that's appropriately sized.

Use a cardboard grade suitable for the product.

Protect fragile items.

Prevent unnecessary movement.

Seal the parcel securely.

And check the requirements of your chosen international courier before sending it.

Because when your parcel has thousands of miles to travel, good packaging shouldn't be an afterthought.

BUILD YOUR CUSTOM-SIZED SHIPPING BOX →

 

James Palfrey-Smith is the General Manager at ASC Direct with extensive experience in both operations and sales. James is passionate about solving packaging problems, delivering fast customer support, and building lasting relationships. Outside of work, he enjoys outdoor activities like hiking and skiing. A fan of real ale and business podcasts, he continuously seeks personal and professional growth. 

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