International express delivery has clear and strict packaging requirements. These requirements are directly related to both cargo safety and transportation compliance. Oversized packages are almost always subject to additional charges, the specific fees depending on the courier’s standards and the extent of the oversize.
I. Core Packaging Requirements for International Express Delivery
International express delivery packaging requirements revolve around three core areas: protection, compliance, and standardization. While requirements vary for different types of goods, the basic principles remain the same.
From a general protection perspective, packaging must be able to withstand compression, vibration, and temperature fluctuations during transportation. For general cargo (such as clothing and books), corrugated boxes must be at least five layers (A-flute or B-flute). Avoid using old, deformed, or damaged boxes, as these boxes are prone to breakage during transit and sorting, resulting in cargo loss. For fragile items (such as glassware and electronic accessories), a dual protection strategy of “internal cushioning + external reinforcement” is required: Bubble wrap, pearl cotton, or foam blocks should be used to fully wrap the interior to ensure there are no gaps between the goods and the carton; Packing tape should be used in a “well” pattern to reinforce the exterior. Some express delivery companies also require “Fragile” warning labels to be affixed to the front and side of the carton, within 10cm of the top.
Specialty packaging regulations are even stricter. For electrically charged items (such as mobile phones and power banks), in addition to complying with lithium battery transportation regulations, packaging must be insulated. Batteries must be individually enclosed in anti-static bags, separated from the equipment, and metal objects (such as keys or paper clips) must not be placed inside the packaging to prevent short circuits and potential safety hazards. Liquid goods (such as cosmetics and reagents) must be sealed in containers. The bottle caps must be wrapped with raw tape and then tightly closed. The outer layer should be sealed with a bag to prevent leakage when inverted. Each bottle should not exceed 100ml. The entire shipment must be wrapped with absorbent cotton and the bottom of the outer carton must be lined with waterproof film to prevent leakage and contamination of other packages. Large goods (such as furniture and machine parts) must be packaged in wooden frames or wooden boxes. Wooden packaging must be fumigated (with the IPPC mark); otherwise, it will be detained and destroyed by customs in the destination country, as untreated wood may carry pests and diseases.
In addition, packaging must meet standardized operating requirements. The surface of the carton must be kept clean, free of old waybills and labels to avoid confusion during sorting and scanning. The weight of the goods and the weight of the packaging must match. For example, the packaging weight of goods under 10kg should not exceed 1kg. Excessive packaging will be considered “invalid packaging” and may require repackaging. Some express delivery companies have specific requirements for packaging materials. For example, DHL prohibits the use of black plastic bags as outer packaging, as these bags prevent clear printing of shipping label information and may result in shipping delays.
II. Oversize Determination Criteria and Additional Charges
Express delivery companies determine “oversize” based on a package’s dimensional weight and actual dimensions. Exceeding these limits will result in additional charges, and the charging process varies slightly between companies.
First, let’s consider the criteria for determining oversize. International express delivery typically charges the greater of “dimensional weight” and “actual weight.” The formula for calculating dimensional weight is (length × width × height) divided by the tonnage weight ratio (common tonnage weight ratios are 5000 or 6000, with DHL and FedEx often using 5000). A package is considered oversize if its actual dimensions or dimensional weight exceed the courier’s basic limits. For example, FedEx’s single-shipment size limits for general cargo are “length + width + height ≤ 300cm, single side ≤ 120cm,” and a volumetric weight ≤ 70kg. If a package’s single side exceeds 120cm but ≤ 175cm, or its length + width + height exceeds 300cm but ≤ 330cm, it is considered “Level 1 Oversized.” If a single side exceeds 175cm or its length + width + height exceeds 330cm, it is considered “Level 2 Oversized,” and some shipping channels will directly reject it.
Secondly, the additional charges are calculated. Oversized charges are typically divided into two parts: a fixed base fee and a weight surcharge, and a fuel surcharge is added. Taking UPS as an example, a Level 1 oversized package incurs a base fee of 180 yuan. If the volumetric weight exceeds 70kg, an additional 20 yuan will be charged for each kilogram exceeding the limit. Level 2 oversized packages incur a base fee of 350 yuan, with an additional 35 yuan per kilogram exceeding the limit. All oversized fees are then multiplied by the monthly fuel surcharge (typically between 22% and 25% in 2025). For example, a package measuring 150cm long, 50cm wide, and 40cm high, weighing 60kg, would have a volumetric weight of (150 × 50 × 40) ÷ 5000 = 60kg. While not overweight, a single side exceeds 120cm, making it a Level 1 oversized package. If the monthly fuel surcharge is 25%, the oversized fee would be 180 × (1 + 25%) = 225 yuan, payable in addition to the base shipping fee.
It is worth noting that some special channels or destinations have stricter restrictions. For example, for packages shipped to remote areas, oversize limits will be tightened (e.g., length + width + height ≤ 270cm), and fees will increase by 30%. For air transport, oversized cargo containing lithium batteries may be subject to an additional “dangerous goods oversize fee” due to cabin loading restrictions, which can reach over 500 yuan per shipment. If a package meets both the “oversize” and “overweight” criteria (e.g., weighing over 100kg), some express delivery companies will charge double the oversize fee, potentially significantly increasing costs.
Third, Pitfall Avoidance Tips: Compliant Packaging and Cost Control Techniques
To avoid additional costs due to non-compliant or oversized packaging, consider both early planning and detailed operations.
During the packaging preparation phase, confirm the cargo attributes and channel requirements in advance. Before mailing, check the packaging specifications of your target courier (e.g., the “Restricted and Prohibited Shipping and Packaging Guide” on their official website). Select materials based on the type of shipment: Use rigid envelopes or small cardboard boxes for lightweight and small items; use five-layer corrugated boxes with wooden frames for larger items; and use custom foam molds for fragile items. If you’re unsure of the dimensions, use a tape measure to measure the length, width, and height of the shipment and use the formula to estimate the volumetric weight to ensure it falls within the limits of your chosen shipping channel. If you’re close to the limits, split the shipment into multiple shipments. For example, split a 130cm long furniture accessory into two 65cm pieces to avoid oversize charges.
When packaging, balance protection with lightweight packaging. Bubble wrap is preferred as cushioning material (it’s lighter than foam). Fill gaps with newspaper or air bags instead of heavy foam blocks to ensure protection while reducing packaging weight. When applying the label, ensure the label information is clearly printed. Center it on the front of the carton and fully cover it with transparent tape to prevent wear and tear during transport. Also, mark the “Length × Width × Height × Weight” on the side to facilitate quick verification by sorters and reduce extra charges due to dimensional miscalculation.
If your shipment is indeed oversized, you should communicate with the courier or shipping agent in advance. Some agents may reduce costs by “split” (sharing volume and weight) or recommend dedicated shipping routes that handle oversized shipments (such as ocean freight, which has more relaxed size restrictions). You can also apply for “oversized cargo pre-declaration” to confirm the fee details in advance to avoid delays caused by disputes upon delivery.
(Note: All fees listed above are for reference only. Please refer to your actual invoice for details. Thank you!)
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