Understanding Carrier Requirements
Each shipping carrier has specific size, weight, and packaging requirements. Understanding these prevents surcharges and ensures delivery.
- •USPS: Max 70 lbs, 130" length + girth combined
- •UPS: Max 150 lbs, 165" length + girth combined
- •FedEx: Max 150 lbs, 165" length + girth combined
- •Oversized surcharges start at different thresholds
Dimensional Weight Optimization
Carriers charge based on dimensional weight or actual weight, whichever is greater. Right-sizing boxes dramatically reduces shipping costs.
- •DIM weight = (L x W x H) / DIM factor
- •USPS retail DIM factor: 166
- •UPS/FedEx DIM factor: 139
- •Oversized boxes can double or triple shipping costs
Selecting Protection Level
Match box strength and cushioning to product fragility and shipping conditions.
- •Fragile items: Double wall, 2-3" cushioning all sides
- •Standard items: Single wall, 1-2" cushioning
- •Heavy items: Heavy-duty bottom, corner protection
- •Consider drop test requirements for your product
Cushioning and Void Fill Options
Proper cushioning prevents product movement and absorbs impact during shipping.
- •Foam inserts: Best protection, higher cost
- •Air pillows: Good protection, lightweight
- •Kraft paper: Economical, recyclable
- •Biodegradable peanuts: Eco-friendly option
Box Style Selection
Different box styles offer advantages for specific shipping needs.
- •RSC: Most economical for standard shipping
- •FOL: Extra strength for heavy items
- •Mailers: Best for flat items and documents
- •Telescope: Variable height adjustment
Cost Optimization Strategies
Strategic box selection and stocking reduces overall shipping costs.
- •Stock 3-5 sizes to cover 90% of shipments
- •Use adjustable boxes for variable products
- •Negotiate carrier rates based on DIM profile
- •Consider zone-based box selection for cost optimization