How to Pack Fragile Items for Postal Safety: A Practical Guide for Sellers

Packing fragile items for postage is both an art and a science. Proper packing reduces returns, breakages and unhappy customers. Below is a hands-on guide covering materials, layering techniques and labelling that help fragile items travel safely through the postal network.

Choose the right outer box

Select a robust corrugated cardboard box with enough room for protective layers. Avoid reused boxes that show signs of wear or water damage. A box that fits the item too tightly can transmit impact forces; too big a box increases movement — both increase risk of damage.

Layering and cushioning

Follow the three-point protection rule:

1. Inner wrap: Individually wrap the item in bubble wrap or foam sheets. For glass, use at least three layers of protective wrap over the most vulnerable points.
2. Fill voids: Use crushed paper, air pillows or biodegradable packing peanuts to fill spaces and prevent movement.
3. Outer cushion: A final layer between the product and box walls reduces shock transfer.

Special techniques for certain products

Electronics: Use anti-static bags and ensure battery removals follow carrier rules. Remove or secure loose parts. Ceramics: Wrap each piece individually and use corner protectors. Clothing: Fold with tissue to avoid creases and use poly mailers for low-cost shipments but avoid for fragile items.

Sealing and reinforcement

Use strong tape (BOPP reinforced) and apply the H-taping method to reinforce the box seams. Avoid overusing tape to the point that the box becomes hard to open for returns inspection.

Label clearly

Include a clear address label and include return address inside the parcel as a backup. For fragile items, add a location label and consider a "Handle with care" sticker; these do not guarantee gentler handling but help visibility during sorting.

Good packing reduces damage rates dramatically — a small investment in quality materials can save you large replacement costs later.

Testing your pack

Before shipping, gently shake the sealed box. If you can hear or feel movement, add more void fill. For high-value items, try a drop test from a height of 1 metre onto different surfaces (carpet, concrete) to ensure the internal protection holds.

Sustainable materials

Consider recycled corrugated boxes, paper-based void fill, and biodegradable bubble wrap alternatives. Many customers prefer eco-friendly packaging, but ensure the material still protects effectively.

Insurance and documentation

For expensive items, declare a value and buy appropriate compensation. Keep photographs of items and packaging before dispatch as proof if you need to claim later.

Summary checklist

• Choose a sturdy box with correct dimensions.
• Wrap items individually and protect corners.
• Fill voids to prevent movement.
• Seal using H-tape and label clearly.
• Test the parcel and photograph packing.

Good packing is the first line of defence against loss and damage. Take the time to do it right and you will reduce returns, protect reputation and save money on claims.