When you ship fragile or high-value goods overseas, the quality of your packing is just as important as the choice of service. Even the best worldwide shipping solution cannot compensate for a weak box, poor cushioning or a crate that fails under pressure. For businesses using Equator Worldwide to move products through demanding global logistics routes, getting the packing right is one of the simplest ways to protect stock, reduce claims and keep customers happy.
This practical guide walks through how to pack and crate items for safe international shipping, including which materials to use, common mistakes to avoid and some expert tips that Equator’s team see working every day.
Start by understanding the journey
Before you reach for a roll of tape, think about what your shipment will actually experience:
- Multiple handling points: collections, sorting hubs, airport and road transfers, final delivery
- Stacking and compression: cartons and crates at the bottom of a pallet or container must withstand heavy loads
- Vibration and impact: conveyor belts, aircraft holds, lorries and vans all create movement
- Changes in climate: temperature and humidity can affect packaging and contents
The golden rule is simple: pack for the worst case, not the best. Assume your box will be stacked, jolted and handled many times on its way through worldwide shipping networks.
Choosing the right box or crate
For lighter fragile goods, a strong corrugated cardboard box may be enough. For heavier or high-value items, you will often need double-wall cartons, wooden crates or a combination.
Consider:
- Weight: anything over about 20–25 kg needs extra strength and internal bracing
- Size: very large items are more exposed to impact and compression and may need crating
- Value: for expensive goods, upgrading the outer packaging is usually cheaper than dealing with damage or loss
For most international shipments, it is worth using brand new cartons or crates. Reused boxes may look fine but often have hidden weaknesses from previous journeys.
Essential packing materials
Good materials make safe packing much easier. A typical kit for global logistics might include:
- Double-wall or triple-wall corrugated cartons
- High-quality packing tape (at least 48 mm wide)
- Bubble wrap or foam wrap for individual items
- Loose-fill chips or crumpled kraft paper for void fill
- Corner and edge protectors for framed items and electronics
- Stretch wrap for bundling and stabilising
- Polystyrene or polyurethane foam inserts for custom cushioning
- Silica gel or desiccant packs for moisture-sensitive goods
For wooden crates, you may also need timber battens, screws, metal brackets and pallet bases. Where possible, use treated timber that complies with international standards to avoid delays in customs.
Step-by-step: packing fragile items in cartons
- Prepare the box
Assemble the carton carefully and seal the base with multiple strips of tape in an H pattern. For heavier items, consider reinforcing the bottom with an extra layer of cardboard inside. - Create a cushioning base
Add 5–8 cm of loose-fill chips, foam or scrunched paper to the bottom of the box. This base layer absorbs shock from drops and impacts. - Wrap each item individually
Wrap fragile items with bubble wrap or foam, paying particular attention to corners and protruding parts. Secure the wrapping with tape so it cannot unravel in transit. - Place items centrally
Put the wrapped items in the centre of the box, not touching the sides. Maintain at least 5 cm clearance on all sides to allow for protective padding. - Fill all voids
Fill any gaps with more void-fill material so items cannot move when the box is shaken. Movement is the enemy of safe international shipping. - Top cushioning and close
Finish with another 5–8 cm cushioning layer on top. Close the flaps and seal with tape in an H pattern. For heavier cartons, add extra tape along seams and edges. - Consider double boxing
For very fragile items, place the packed box inside a second, larger box with another 5 cm of padding all around. This “box-in-box” method offers excellent protection at relatively low extra cost.
Crating: protecting heavy or high-value shipments
When goods are too heavy, bulky or valuable for standard cartons, wooden crates provide the strength and security needed for worldwide shipping.
Key points to consider:
- Design around the item
The crate should fit the item closely, allowing space for foam or other cushioning but not so much that the contents can shift. - Use blocking and bracing
Heavy objects should be blocked with timber and braced so they cannot move up, down or sideways. Movement can shatter internal components even if the crate looks intact. - Distribute weight evenly
Place the heaviest part of the load at the bottom and spread weight evenly across the base. This reduces strain on the crate and makes handling safer. - Fix to a pallet base
For ease of handling through global logistics networks, build the crate on a pallet or skids designed for forklift access. - Securely close and seal
Use screws rather than nails where possible, so crates can be opened and reclosed at customs without damage.
Common packing mistakes to avoid
Even experienced shippers sometimes fall into habits that increase risk. Some of the most frequent issues include:
- Under-filling boxes
Cartons that are only half full are much more likely to crush or collapse. Either cut down the box or add internal filler to fully support the structure. - Overloading cartons
Cramming too much weight into a single box strains the cardboard, tape and handlers. Spread heavy items across multiple boxes where practical. - Using newspaper as the main protection
Newspaper offers limited cushioning and can compress, leaving items exposed. Use professional void-fill materials instead. - Relying on “Fragile” labels alone
Labels help, but they are not a substitute for robust packing. Assume your box will be handled like any other, regardless of the stickers. - Exposed branded packaging
Leaving high-value retail boxes unprotected can attract unwanted attention. Always place branded packaging inside a plain outer carton.
Labelling, paperwork and insurance
Good packing should be matched with clear labelling and complete documentation:
- Attach the full delivery address and return address in a waterproof pouch
- Include a packing list inside and, where required, on the outside for customs
- Use orientation arrows (“This way up”) and handling labels to support safe handling
However well you pack, no method eliminates risk entirely. For valuable goods, discuss cover and liability options with your provider so your worldwide shipping is backed by appropriate protection.
When to involve the experts
DIY packing and crating can work extremely well when you follow best practice, but there are times when expert help is essential. If you are shipping:
- Very high-value goods
- Extremely fragile items such as artwork, glass or delicate instruments
- Oversized machinery or complex equipment
- Regular high-volume exports
…it is worth speaking to Equator Worldwide for tailored advice or professional packing solutions.
As a specialist in global logistics, Equator can advise on the best packing methods for your product, the right balance between cost and protection, and how to meet carrier and customs requirements for international routes. Whether you handle packing in-house or use professional services, following these principles will help your shipments arrive safely, protect your reputation and make your worldwide shipping operations more efficient and reliable.