How to pack fragile items for shipping

The materials and methods you use to pack fragile items depend largely on the type of products you’re shipping. Various packaging materials are available to ensure that your items are safely delivered, no matter how big or small. 

So if you’re planning to send a fragile parcel for the first time, knowing how to properly package these items is just as important as choosing the right overseas shipping provider.

The importance of proper packaging for fragile shipping

During transit, your package will encounter multiple stress factors, including vibration, pressure from stacking, accidental drops, humidity, and more. Without strong, well-planned packaging, these conditions can easily compromise the quality and condition of your shipment.

A compromised shipment could lead to refunds or replacements, and in the long run, potentially affect how customers perceive your brand and impact your sales. With how competitive the e-commerce industry can be, ensuring a smooth and reliable delivery process is imperative in building customer trust. Secure packaging not only demonstrates your brand’s professionalism and attention to detail but also increases the likelihood of repeat purchases.

Essential packaging materials for fragile shipping

To build durable and reliable packaging for fragile items, you need the right combination of internal and external materials. Each layer combined is important in keeping your products protected throughout their journey overseas.

Internal packaging materials

Internal cushioning helps absorb shocks, prevent collisions, and keep your item from moving around during shipping. With many types of inner packaging available, choose one that best matches the size, weight, and fragility of your item:

• Bubble wrap: This type of protective wrapping is ideal for packaging individual items. The air-filled pockets provide excellent protection against impact and vibration.
• Packing peanuts: They are suitable for filling voids in the box, preventing items from shifting. Packing peanuts work especially well for lightweight items or irregularly shaped products.
• Foam inserts: These inserts are typically used for electronics, glassware, and premium goods that need snug, made-to-fit protection. Foam absorbs shock and keeps items firmly in place.
• Air pillows: Lightweight and clean, these are best used to block and brace items within the box, adding an extra buffer around the product.

External packaging materials

External packaging serves as the main structure that houses your fragile items and shields them from pressure, drops, and compression during transit. When strong external packaging is paired with effective internal cushioning, you create a robust protective system that forms the foundation of safe, reliable fragile shipping. To protect your fragile packages, follow these recommendations:

• Use a high-quality corrugated cardboard box: Opt for double-wall or tri-wall construction, especially when shipping heavy, delicate, or high-value items. These boxes are designed to withstand stacking, handling, and transport stresses.
• Avoid reusing old boxes: Previously used boxes may look intact, but can have weakened fibers, softened edges, or hidden moisture damage. This significantly reduces their ability to protect fragile items.
• Check the box’s weight rating: Always choose a box with a weight rating higher than the combined weight of the item and the cushioning materials. This ensures the box will hold up during handling and transit.

Expert packaging techniques for safe transit

Once you’ve selected the right packaging materials for your fragile items, the next step is learning how to use them effectively. Applying proper wrapping and packing techniques keeps your items throughout their journey, especially during overseas shipping, where handling conditions can vary. Some of the ways you can pack your fragile items include the following:

1. Wrap items separately and use dividers

When shipping multiple fragile items together, wrap them individually to prevent direct contact, friction, and the risk of impact between items. When doing so, ensure to

• Wrap each item in bubble wrap or foam sheets for complete surface protection.
• Secure the bubble wrap or foam sheets tightly with packing tape.
• Place each item separately inside the box using cardboard dividers, partition inserts, or smaller inner boxes.
• Maintain an additional buffer zone between each item and the walls or corners of the box. This gap acts as a protective cushion, helping absorb external pressure and minimise damage from accidental drops or rough handling.

2. Leave no empty space

Inside a fragile parcel, empty space is one of the main causes of damage. Any movement during transit, even slight vibration, can lead to cracks, chips, or breakage. To eliminate gaps, fill all voids with packing peanuts, air pillows, or crumpled kraft paper.

However, avoid over-packing. Excessive stuffing can distort the shape of the box, weaken its structural integrity, and increase the likelihood of tearing or bursting during transit.

3. Use the double-boxing method

For highly delicate, expensive, or sensitive items, the double-boxing method offers an added layer of security. It provides an extra buffer zone that reduces the impact of external force, which could be beneficial for fragile items for international or long-distance shipping. During handling and stacking, this method helps prevent crushing, spreads out pressure, and greatly improves survival rates. To use the double-boxing method:

• Pack your item securely in a sturdy inner box using bubble wrap, foam, or other cushioning.
• Add more cushioning material (air pillows, foam sheets, or packing peanuts) to the bottom of a larger, stronger outer box.
• Place the inner box inside the outer box.
• Fill the remaining space around the sides and top with cushioning to prevent movement.
• Seal the outer box carefully.

4. Secure the package using the H-taping method

Proper taping prevents the box from opening, splitting, or collapsing. Use strong, pressure-sensitive packing tape rated for the weight of your package. Avoid using office tape, masking tape, or duct tape, as these lack the adhesive strength needed for fragile shipping. To apply the H-taping method:

• Seal the center seam of the box with packing tape.
• Apply tape along the two side seams, creating an “H” shape.
• Reinforce corners and edges for heavy or high-value parcels.

5. Affix fragile and special handling labels

Labels help ensure your package is handled with the appropriate level of caution throughout its journey, especially during loading, unloading, and sorting. While they don’t necessarily guarantee gentle handling, they provide important visual cues that influence how carriers handle and position your parcel. Use labels, such as “Fragile” or “Handle with Care”. Place them on multiple sides of the box for maximum visibility.

How DHL Express supports you in shipping fragile parcels

Even with the most carefully wrapped items, choosing the right shipping partner is critical to ensuring successful overseas delivery. This is where partnering with DHL Express can help you. 

Working with numerous businesses in Cambodia, DHL Express has extensive experience helping companies navigate the challenges of fragile shipping, …especially for international shipments. Our team is trained to handle fragile items with extra care, ensuring they arrive safely and on time. And with our global network, you can expect reliable transit and seamless logistics support whether your package is headed to Asia, Europe, or the US.

In addition, real-time tracking allows both you and your customers to monitor shipments at every stage, providing transparency and peace of mind. For added security, you can also include shipping insurance, which is especially valuable for high-value, fragile items during long-distance transport.

By partnering with DHL Express, you not only benefit from faster and more reliable overseas shipping, but you also reduce the risks associated with transporting fragile goods. This enables you to deliver consistently excellent service, strengthen customer trust, and protect your brand reputation.

Open a business account with DHL Express today and ensure your fragile items arrive safely every time.