Packaging Compliance Guide
Make sure your package meets carrier standards. Avoid rejected shipments and surcharges.
Universal Packaging Requirements
| Requirement | Standard | Why It Matters |
|---|---|---|
| Box condition | New or like-new, no holes, no wet spots, no crushed corners | Weak boxes cause damage claims |
| Minimum cushioning | 2 inches of padding on all 6 sides for fragile items | Required for insurance claims |
| Tape type | 2-inch pressure-sensitive packing tape or water-activated tape | Masking/duct tape fails in sorting machines |
| Label placement | Largest flat surface, no seams, no edges, clear and readable | Scanners need clear labels |
| Old labels | Remove or cover ALL old labels, barcodes, and markings | Old barcodes cause misrouting |
| Sealing | H-taping method: center seam + both edge seams | Prevents box opening in transit |
| Weight distribution | Heaviest items at bottom center of box | Prevents tipping and shifting |
Carrier-Specific Requirements
| Rule | USPS | UPS | FedEx |
|---|---|---|---|
| Max weight | 70 lbs | 150 lbs | 150 lbs |
| Max length | 108 in | 108 in | 108 in |
| Max girth+length | 130 in | 165 in | 165 in |
| Label barcode type | Intelligent Mail | MaxiCode | FedEx barcode |
| Can reuse box? | Yes if clean | Yes if sturdy | Yes if no old labels |
| Poly mailer OK? | Yes | Yes (non-rigid) | Yes |