Furniture, machinery, tools and oversized cargo — palletised, strapped and corner-protected for international freight.
Large and heavy items require a different approach to standard parcel packing. Most couriers have weight limits of 30–70 kg per parcel and maximum dimension limits (typically 120×80×80 cm or combined girth + length limits). Items exceeding these limits must be palletised or shipped as freight. For items that fit within courier limits (e.g. heavy machine parts, large power tools, flat-pack furniture), the key challenges are structural box integrity under compression and correct weight distribution so the base doesn't burst. For pallet shipments (furniture sets, industrial equipment), the focus shifts to securing the load with stretch wrap, ratchet straps, and corner guards so nothing shifts or falls during forklift handling and transit.
Before boxing anything, confirm the carrier's limits. DHL parcels: max 70 kg, max 120×80×80 cm. UPS: max 70 kg, max length + girth 400 cm. GLS and DPD have similar limits. Items outside these limits must go as pallet freight. Use Cargosender to compare pallet freight rates for oversized loads.
For heavy items (over 15 kg), use double-wall corrugated boxes rated for the item's weight. For items over 30 kg, use triple-wall corrugated or a wooden crate. Check the Box Compression Test (BCT) rating printed on the box flap — it tells you the maximum stacking weight the box can support.
For flat-pack furniture or modular machinery, disassemble into its component parts and wrap each piece individually. Smaller, wrapped components are far easier to pack safely than assembled units. Keep all fasteners, screws and assembly instructions in a clearly labelled bag taped inside the box.
Attach cardboard or foam corner guards to all vulnerable edges and corners. Corners sustain the highest impact force in transit. For machinery with protruding bolts or fittings, wrap each protrusion in foam and tape flat against the main body.
Place the heaviest component at the base of the box, lightest on top. Fill all voids with high-density foam blocks or packing paper. The item must not shift when the box is tilted or turned. Reinforce the base of the box with extra tape strips running both lengthways and crossways.
Arrange items on the pallet with the heaviest at the base. Wrap the entire pallet load in 3–5 layers of stretch wrap, working from bottom to top. Apply ratchet straps over the wrap for additional security. Attach the delivery address and pallet shipping label to at least two sides. Mark 'DO NOT STACK' if the load cannot bear additional weight from above.
Using single-wall boxes for items over 15 kg — these will collapse under the item's own weight during transit. Always use double-wall minimum for heavy goods.
Packing heavy items at the top of the box — weight must sit at the base for stability and to prevent the box bottom from bursting open.
Not reinforcing the box base — apply 3 strips of heavy-duty tape across the base in a grid pattern before adding any items.
Palletising without stretch wrap — individual boxes on a pallet without wrap will slide and topple during forklift movements. Wrap every pallet load.
Ignoring carrier weight limits and booking a parcel service for a 50 kg shipment — overweight parcels are rejected at collection or attract significant surcharges.
Not protecting metal protusions on machinery — bolts, axles and fittings can pierce box walls and damage other cargo or injure handlers.
Use foam-in-place kits for irregularly shaped machinery or equipment — the expanding foam creates a perfect custom-fit insert that no pre-cut foam can match.
For pallet shipments, choose a pallet size that matches your load footprint — don't use a full EUR pallet for a small load, as unused pallet space is wasted dimensional weight.
Always photograph the packed pallet or box from all sides before collection — essential evidence for any damage or shortage claim.
For furniture with glass components, remove and ship the glass separately as a fragile parcel — never ship glass attached to wooden furniture frames.
Use L-shaped cardboard edge protectors on every corner of a pallet load — they add structural rigidity and prevent ratchet straps from crushing the outer boxes.
Mark the loading orientation clearly — 'HEAVY BASE — DO NOT INVERT' with arrows showing the upright direction.
Weight limits vary by courier: DHL accepts up to 70 kg per parcel, UPS up to 70 kg, FedEx up to 68 kg, GLS up to 50 kg, DPD up to 50 kg. Items exceeding these limits must be shipped as pallet freight. Cargosender allows you to compare both parcel and pallet freight rates.
Use a pallet when: your item or combined shipment exceeds 70 kg, when dimensions exceed 120×80×80 cm, when you are shipping multiple heavy boxes together, or when the item is fragile and needs to be kept on its base throughout transit. Pallet freight is handled with forklifts and avoids conveyor belt sorting — better for very heavy or fragile large items.
Yes, if each package is within the courier's size and weight limits. Flat-pack furniture (IKEA-style) typically ships well by courier as individual wrapped packages. Larger assembled or bulky furniture (sofas, wardrobes, dining tables) requires pallet freight or a specialist furniture courier service.
Volumetric weight (also called dimensional weight) = (Length × Width × Height in cm) ÷ 5000 (DHL/FedEx/UPS formula). If the volumetric weight is greater than the actual weight, you pay the volumetric rate. For large, lightweight items this can make shipping expensive — consider disassembling or repackaging to reduce dimensions.
Heavy machinery typically requires a wooden crate or bolted wooden frame to provide rigid structural support during forklift handling. The machine must be secured (bolted or strapped) inside the crate, with foam or rubber blocks preventing movement. Crating services are offered by specialist packaging companies and freight forwarders.
Now that your large & heavy items are packed, compare DHL, UPS, FedEx, DPD and GLS rates — get an instant quote from Cargosender in seconds.
Get a Free Quote →