Shipping with FedEx? Why Your Own Cardboard Box Could Be the Better Choice

FedEx provides its customers with a range of packaging options, including reusable plastic Paks. But restrictions on where FedEx-supplied packaging can be used mean that sometimes you'll need to provide your own packaging – so why not choose a cardboard box made to fit your product?

If you regularly send products with FedEx, you might be familiar with their range of complimentary packaging.

Depending on the service you're using, this can include envelopes, reusable Paks and cardboard boxes.

But FedEx doesn't allow all of its packaging to be used with every service.

For domestic UK shipments, FedEx currently states that only its FedEx Reusable Large Pak can be used from its supplied packaging range, although customers can use their own packaging.

FedEx also states that its packaging should not be used for International Economy Services within Europe, meaning you'll need to provide your own suitable packaging.

So, if you're supplying the packaging yourself, what should you use?

For many products, a strong, right-sized corrugated cardboard box can be a great place to start.

Can I use my own cardboard boxes with FedEx?

Yes.

FedEx allows customers to use their own packaging, providing it is suitable for the product and shipping service being used.

In fact, FedEx's own packaging guidance repeatedly emphasises the importance of choosing the right packaging for the job.

That doesn't necessarily mean finding the biggest or strongest box you can.

It means choosing packaging that's appropriate for what you're actually sending.

And that's where right-sized cardboard boxes can help.

Why choose a cardboard box instead of a shipping bag?

Shipping bags certainly have their place.

Soft, lightweight and non-fragile products can often be transported perfectly well in suitable mailing bags.

But not everything should be squeezed into a bag.

If you're sending something that's:

• Fragile
• Easily crushed
• An unusual shape
• Valuable
• Made from glass or ceramic
• Vulnerable to knocks
• Made from several components
• In retail packaging you don't want damaged

then a corrugated cardboard box can provide much greater structural protection.

A bag largely follows the shape of what's inside it.

A cardboard box creates a protective structure around the product.

Better protection starts with the right-sized box

Choosing a cardboard box doesn't mean putting a small product into a huge box.

In fact, we'd recommend the opposite.

A box should be appropriately sized for the product you're sending, allowing enough room for any protective packaging that's genuinely required without leaving excessive empty space.

Why?

Because empty space allows products to move.

If a product can slide, roll or bounce around inside its packaging during transportation, you're likely to need additional void fill to keep it secure.

Start with a box that's closer to the size of the product and there's less empty space to deal with.

Less movement. Less unnecessary void fill. Better use of packaging.

Reduce your reliance on plastic packaging

There's another reason businesses are reviewing how their products are packaged.

Plastic.

FedEx itself has been introducing reusable packaging, including Paks with dual adhesive strips that allow the packaging to be used for a second shipment.

Reusing packaging is one way of reducing waste.

Another option is to look at whether plastic packaging is required in the first place.

For products that are suitable for cardboard boxes, moving towards predominantly paper and cardboard-based packaging can reduce your reliance on plastic.

And it doesn't have to stop at the box.

Think about the whole parcel

If your aim is to reduce plastic packaging, changing from a plastic mailing bag to a cardboard box is only part of the story.

Look at everything you're using to prepare the shipment.

You could combine:

A right-sized cardboard box

Paper-based protective packaging such as HexcelWrap®

Paper packaging tape

This creates a predominantly paper and cardboard-based packaging solution while still providing the protection your products need during transportation.

It's not about removing packaging for the sake of it.

It's about using the right amount of the right materials.

Why does right-sizing matter when shipping with FedEx?

There's another practical reason to avoid unnecessarily large boxes.

The dimensions of your package can matter when it comes to shipping costs and surcharges.

FedEx applies dimensional criteria to some of its additional handling and oversized package charges.

From January 2026, for example, FedEx UK introduced additional volume criteria as part of its Additional Handling Surcharge and Oversize Charge rules.

That doesn't mean every slightly oversized box will automatically cost you more.

But it does reinforce an important principle:

There's little benefit in shipping fresh air.

If two boxes provide the same level of protection but one is significantly larger than necessary, you're using more cardboard, taking up more transport space and potentially affecting the way your shipment is charged.

Use less void fill

This is one of the biggest benefits of getting your box size right.

Imagine your product measures:

300mm × 200mm × 100mm

but you're using a stock box measuring:

450mm × 350mm × 250mm

The product might fit inside easily, but that's not necessarily a good thing.

You're now left with a significant amount of empty space.

So you fill it.

Paper, air pillows, bubble wrap or another void-fill material gets added simply to stop the product moving around.

Protective packaging is important when a product genuinely needs cushioning.

Filling empty space created by an oversized box is different.

A custom-sized box allows you to reduce that unnecessary space from the beginning.

Could a right-sized box reduce damage?

No packaging can guarantee that a product won't be damaged during transportation.

Parcels have to make their way through collection, sorting, transportation and final delivery.

That's why appropriate packaging is so important.

A well-fitting corrugated cardboard box can help protect products against knocks and compression while reducing unnecessary movement inside the package.

Additional cushioning can then be added around fragile areas where it's actually needed.

That's a much more considered approach than simply placing the product into the nearest available box and filling the remaining space.

What about sustainability?

Cardboard has another important advantage: established recycling infrastructure.

Once tape, labels or other non-paper components are dealt with as appropriate, corrugated cardboard can generally enter household or commercial paper and cardboard recycling streams.

You can make things even simpler by considering the other materials you use.

For example, switching from conventional plastic parcel tape to paper packaging tape can help keep your packaging predominantly paper-based and make recycling easier for the recipient.

Likewise, paper-based protective packaging can provide an alternative to traditional plastic bubble wrap for suitable products.

At ASC Direct, the cardboard boxes we manufacture use FSC® Mix 70% certified material and contain a minimum of 70% recycled content.

But sustainable packaging isn't just about the material.

Using less unnecessary material in the first place matters too.

Do I need to use a standard-sized FedEx box?

No.

If you're using your own packaging, you don't have to make your product fit a predetermined box size.

That's where custom packaging becomes particularly useful.

Rather than starting with:

"What box sizes can I buy?"

start with:

"What size box does my product actually need?"

Measure your product, allow sufficient room for the protection it requires, and create a box around those dimensions.

This can be particularly useful for businesses regularly sending the same products through FedEx.

What if stock cardboard boxes are cheaper?

They often are.

Standard cardboard boxes can be manufactured in their thousands, making them extremely cost-effective.

If you can find a stock box that fits your product well, there's absolutely nothing wrong with using it.

But if the stock box is considerably larger than your product, it's worth looking beyond the price of the empty box.

Consider:

• How much void fill you're using
• How long each parcel takes to pack
• How much storage space your flat-packed boxes require
• How much space finished parcels occupy
• Whether products can move around inside the box
• Whether the finished parcel is larger than it needs to be

Sometimes the cheapest box isn't necessarily the most efficient packaging solution.

Custom-sized FedEx shipping boxes from just 25 boxes

If you regularly ship products through FedEx and can't find a suitable stock box, ASC Direct can manufacture cardboard boxes to the dimensions you require.

Our online Box Builder lets you specify your required internal length, width and depth, select your box style and board grade and get an instant price.

And you don't need to order thousands.

Custom-sized cardboard boxes are available from just 25 boxes, making them suitable for small businesses as well as larger ecommerce and commercial operations.

Shipping with FedEx? Start with the product, not the packaging

FedEx hasn't banned plastic shipping bags but they are actively speaking with their customers to discuss using less plastic bags.

In fact, reusable Paks remain part of its packaging range and can be a perfectly appropriate solution for certain shipments.

But FedEx is increasingly focusing on reusable and recyclable packaging, while restrictions also mean that its own supplied packaging can't be used with every service.

If you need to provide your own packaging, that's an opportunity to reconsider what you're using.

For soft, lightweight products, a suitable mailing bag may still make perfect sense.

For products requiring more structural protection, a right-sized corrugated cardboard box could be the better option.

And rather than choosing the closest standard size and filling the empty space, why not make the box fit the product?

Less empty space. Less unnecessary packaging. More appropriate protection.

BUILD YOUR CUSTOM-SIZED FEDEX 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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