Packing with Care

Retail packaging is not usually enough to provide adequate protection during transit, so use the box-in-box packing technique.

• Inspect the item before packing to ensure it is not damaged
• Repack the item in its original packaging with any interior cushioning supplied
• If the original packaging is damaged or unavailable, wrap the item in at least 2.4 inches of bubble wrap and source a strong box at least 5.5 inches larger than the inner box in all dimensions
• Use a dual-wall box for heavier items
• Place 2.4 inches of filler material at the base of the box before placing the inner box or item inside
• Ensure a gap of at least 2.4 inches around the item on all sides and fill all spaces with filler material
• Alternatively, use foam corners to keep a sufficient gap between the item/inner and outer box
• Close and seal the box by H-taping with pressure-sensitive tape

Lithium-ion batteries are subject to strict shipping regulations. Typically, a non-account holder can only ship one laptop with one battery per package. Explore our Dangerous Goods FAQs for full details and information on Dangerous Good packaging.

Specialist protective packaging solutions are available from DHL Express for mobile phones or tablet computers. Contact Customer Service for more information. If using your own packaging, ensure that the device is surrounded with at least 2.4 inches of suitable filler material such as bubble wrap, before placing inside a strong dual-wall corrugated box.

For laptops or desktop PCs, use specialist transport boxes available from DHL Express in most markets. Ensure that the power button is taped to prevent activation, and consider removing or encrypting sensitive data for security.

Use the original protective packaging materials with intact foam cushioning and employ the box-in-box method for added protection.

For fragile items, use a dual-wall corrugated box rated to the correct size and weight. Pack the contents so that they are well cushioned with at least 2.4 inches of separation from the external walls of the box.


Ensure multiple items are well separated from one another. For added protection use the box-in-box packing method.


For lighter, non-fragile items, single-wall corrugated packaging is usually sufficient.  If packaging needs to be retail-ready, consider overpacking to avoid cosmetic damage.


Need DHL packing supplies or DHL packing guide? Contact Customer Service.

Our Flyer Bags are specially designed for low-value clothing. If you wish to use your own flyer bag, ensure it has the correct tensile and seam strength for transport - allowing the bag to stretch 13.8 inches before failure. DHL Express Flyer Bag seams use glue that is stronger than the bag itself.

For low-value clothing items under 6.6lbs, place the item in a closed shoe box, then insert it into a large DHL Express Flyer Bag or similar. Seal the Flyer Bag, tape any excess material, and make sure the transport label is clearly visible.

For high-value items or shipments over 6.6lbs, follow basic packing instructions and place all items into a strong outer box. Fill any voids and secure the flaps using the H-taping method. Ensure the transport label is visible.

Fragile items should be packed individually in a dual-wall box or a specialist box. We do not recommend the use of orientation-dependent boxes such as wardrobe boxes. Each item must be wrapped in small cell bubble wrap, with at least 2.4 inches of separation from the walls of the box, and the flaps secured with H-taping. Ensure to apply a "fragile" label for clear identification.

Since shoe boxes may not adequately protect shoes during transit, they must be overpacked. If the shoes are low-value or single-piece under 6.6lbs, follow the same steps as for low-value clothing by using a shoe box inside a DHL Express Flyer Bag. For heavier or multiple pairs, use appropriate box packing.

Non-fragile clothing can be shipped in a sealed plastic flyer bag or single-wall cardboard box. Each piece should be separated to avoid damage during transit. Use the appropriate box size to prevent collapse due to void space.

DHL Express provides a range of specially designed packaging solutions tailored for different temperature needs:

Each box is supplied as a complete solution and includes handling instructions specific to each temperature category.

DHL Express can also provide dry ice or coolant wrap preconditioning services, as well as temperature monitoring solutions. 

Please contact Customer Service for more information.

Designed for the transportation of Category B UN3373 biological samples, DHL Express offers three packaging solutions for different temperature environments: ambient non-insulated, ambient insulated and ambient extreme. All solutions include an outer carton: measuring 9.3 x 7.6 x 4.8 inches with space for 6 x 10ml vials for insulated and non-insulated items - and measuring 11.4 x 9.5 x 7 inches with space for 6 x 10ml vials for ambient extreme items), 1 x 209.4 lbs bag and 1 x absorbent sleeve.

For non-temperature-sensitive biological substances, ambient non-insulated packaging also includes 1 x bubble bag. 

For temperature-sensitive biological substances, ambient insulated packaging offers an extra layer of protection with 1 x air pillow, 2 x coolant wraps and 1 x insulated liner.

For thermal protection from extreme temperature fluctuations, ambient extreme packaging provides 2 x coolant wraps and 1 x EPS box.
 
If transporting Category B UN3373 biological samples, the sender must comply with all local and international laws on classifying, packing and labelling these shipments and must be shipped according to IATA and ICAO regulations. Any shipments that do not conform to local and international regulations will not be accepted by DHL Express. The advice given does not replace any shipping regulations or IATA or ICAO instructions.

Designed to cope with a controlled room temperature environment between 15ºC and 25ºC for up to 72 hours, these boxes are available in small, medium and large sizes, supplied with different-sized Pharmacool Cassettes. Handling instructions for summer and winter temperature profiles are also provided to allow for preconditioning of the Pharmacool Cassettes.

Designed for environments between 2ºC and 8ºC for up to 108 hours, these box sizes are the same as those used to ship contents at controlled room temperatures. The preparation of the Pharmacool Cassettes will create a chilled environment which will be maintained for the desired time. Available instruction sheets will guide you through the correct preparation process.

Yes. Dry ice is the most commonly used refrigerant to maintain temperatures below -20C, For transport by air, dry ice is regulated and considered a dangerous good. It sublimates and displaces oxygen so boxes should never be hermetically sealed. These solutions ensure air pressure does not build up and a sub -20ºC environment can be maintained for up to 129 hours.

Dry ice is available in forms such as pellets, sticks or plates and a supply service can be arranged separately. Please speak to your DHL Express Sales Executive for details.

Yes. The combination temperature solution is an addition to the DHL Express Thermo Packaging range and can accommodate the shipping of frozen and ambient samples within a single box.

Strict weight and dimensional restrictions apply to pieces carried through the DHL Express network to ensure that all goods can be handled safely and securely in ouir facilities and transport modes.


• Each piece must not exceed 2200 lbs
• Total shipment weight must not exceed 6600 lbs
• DHL Express does not accept pieces with lengths above 118 inches
• Pallet height should not exceed 63inches
• Use standard-sized pallets for shipments with Width × Length up to 47.2 inches

Large or palletised pieces need to be packed so they can be handled by DHL Express’ uniform network of trucks, aircraft and automated facilities. They need to be suitable for stacking, forklift handling, tilting and vibration.


• Stackable: Ensure items can be stacked or have items stacked upon them
• Forkable: Pieces > 154.3 lbs must be on a fork-movable crate or pallet
• Tilting: Goods should be secure and stable on the pallet and within packaging - as they will tilt during flight
• Shock & vibration: Protect goods against vibrations and minor shocks

Choose packaging by weight, size and structural needs—boxes for lighter goods, crates for heavy/large items, pallets for bulk.


• ≤ 55.1 lbs: Boxing acceptable (box must support full weight); caution for long/narrow boxes >40 inches. Reinforce the packaging or opt for crating 
• Heavier larger items e.g. engines, industrial equipment >55.1 lbs: Using a crate is recommended with quality hardwood, diagonal bracing; wood must be heat- or chemically-treated for international use. If using a box, it must be capable of supporting the full weight of the goods. Due to the weight, special handling equipment that includes forklifts will be required to move the item and if packed incorrectly your piece may be refused collection 
• For bulk or heavily boxed pieces >154.3 lbs: Must be in fork-movable crate or securely loaded to a pallet. Ensure a level, even top surface and no box overhang

Select pallet material by weight, environment and reusability requirements; only standard-sized pallets ≤120 cm length/width should be used.


• Wooden: Strong, suitable for heavy items, reusable, widely available and cost-effective vs plastic; ensure international wood treatment standards for the market where it will be used. Use bottom bracing to increase stability
• Plastic: High loading capacity, anti-slip surface, humidity and corrosion resistant, low weight, more expensive than wood
• Cardboard: Lightweight, 100% recyclable, single-use only, not suitable for heavy items or humid environments, low cost

Use stacking patterns that preserve box strength and create a level top surface; avoid methods that reduce compression resistance or expose goods.


Do use:


• Column stack: Stack corner-to-corner and edge-to-edge — offers best compression strength during transit. Secure with banding or stretch-wrap
• Interlocking stack: Increases stability if boxed contents are rigid; if not rigid, this can reduce compression strength by ~50%. Stack boxes corner-to-corner and edge-to-edge

Avoid:

• Pyramid stack: Creates uneven top surface and is not recommended; if stacking an odd number of boxes, use empty boxes to maintain a level top surface or ship excess as loose pieces
• Overhang stack: Never allow boxes to overhang pallet edge as it unduly exposes goods to damage and reduces individual box strength by >30%

Use edge protection, paperboards and bracing to stabilize loads, spread top loads and prevent lateral movement.

• Vertical and horizontal edge protectors reduce edge damage and stabilise the load
• Paperboards on top, base and sides spread weight of shipments placed on top of and against base pallet slats
• Brace outsize pieces (e.g., cable reels, engines) to the pallet with wood/metal to prevent sideways movement
• Use additional protection (foam, moulded inserts, wooden crating) as needed

• Ship in a crate or securely braced to a pallet and squarely covered with reinforced cardboard and edge protectors
• All liquids/fuels must be drained prior to transport
• Parts must not overhang the pallet; if they don’t squarely fit, use a crate or appropriately sized fork-movable base

Tyres must be stabilised on a pallet and protected to prevent wall damage; loose tyres are not accepted.

• Shrink-wrap tyres to a standard pallet and secure with metal or unbreakable plastic banding
• Place cardboard, wooden or plastic protector boards on top of the tyre wall
• Custom tyre boxes must support tyre weight and have flat, non-rounded edges

Industrial equipment:

• Crate or securely braced to pallet; squarely cover with reinforced cardboard and edge protectors; drain all liquids/fuels; large top-heavy items should be loaded on a wide base

Cable reels/spools:

• Must be palletized (no loose reels)
• Load reel sideways on appropriately sized pallet so that items can be safely stacked on top
• Heavy reels >55.1 lbs: Brace with wooden blocking and secure with 2 horizontal and 2 vertical metal or unbreakable plastic straps

Glass/panels require protective internal cushioning, a sturdy outer box or crate, and clear labelling to prevent torsion and handling damage.

• Package inside a box or wooden crate
• Surround the panel or glass edge with styrofoam piping and fully cover with bubble wrap
• Use specially moulded styrofoam inserts suitable for the size of the outer box around all edges of the glass or panel
• The panel and moulded inserts must then be placed inside a two-wall corrugated outer box
• The styrofoam inserts should prevent any movement of the panel or glass within the box, and maintain a minimum separation distance of 2.4 inches from the outer box wall
• Affix “GLASS” special handling labels on all sides

• Ship on plastic or hardwood pallet with plank gaps <0.8 inches
• Place fibreboards on top, in between drums and the pallet base to prevent movement and damage
• Secure drum to pallet with minimum two metal or unbreakable plastic straps; use corner cleats/strap protectors to prevent cosmetic damage to drums
• When shipping multiple drums, band drums together before securing to pallet
• Maximum acceptance: three pallets, combined weight must not exceed one ton

Use manufacturer or heavy-duty overpack for TVs; hard cases are required for luggage, sports gear and instruments, with additional boxing if needed.

Large TVs:

• Fill voids in original packaging; overpack in double-walled box if manufacturer packaging lacks double walls
• When shipping multiple TVs, use a pallet large enough to avoid overhang; secure with unbreakable straps and shrink-wrap; add cushioning on top and paperboards covering sides
  

Luggage, sporting goods, musical instruments:

• Ship in hard cases (soft cases are not suitable for Express transportation); for extra protection put hard case inside an outer cardboard box
• If no hard case is available, use double-walled box with multiple layers of large-cell bubble wrap and fill all voids
• Ensure items are fully encased and no parts protrude
• DHL Express does not supply specialist packaging for sporting or musical equipment

Long items must be supported to prevent bending and overhang. Items >118.1 inches are not accepted.


Long tubes/pipes/binds:

• Long items must be supported to prevent bending and overhang. Items >300 cm are not accepted
• Use triangular packaging or spiral-wound tubes inside a box
• Items >55.1 lbs must be in crates and secured to pallet

Carpets & textile rolls:

• Roll along shortest length around strong tube
• Protect ends with strong coverings
• ≤55.1 lbs: use double-walled boxes
• >55.1 lbs / > 39.4 inches: use crates or pallets with strapping and shrink wrap

Non-compliant packaging creates risks to shipments, equipment and personnel.

• DHL Express may refuse to accept, pick up or process the shipment
• Additional handling surcharges may apply in some cases; check country-specific DHL Express surcharges

• Contact customer service for assistance
• For large/heavy items unsuitable for DHL Express, DHL Global Forwarding is available