How to Protect Fragile Items when Shipping

Bob

July 25, 2025

E-Commerce Insights

Shipping fragile items isn’t easy. One small mistake, and your product could arrive broken.

It means more returns.

Many unhappy customers.

Receving bad reviews.

If you run an eCommerce business, you know how serious this can be. A few damaged shipments can hurt your brand—and your bottom line.

But here’s the good news: most of this is preventable.

In this guide, you’ll learn how to pack and ship fragile items the right way. Step by step. From choosing the right box to sealing it properly. We’ll show you what materials work best, what mistakes to avoid, and how to reduce the risk of damage.

We’ve helped over 100 brands ship their products safely with custom packaging. And we’ve kept quality complaints low by designing packaging that works.

So if you’re tired of damaged goods and lost business, you’re in the right place. Let’s fix it.

What makes an item fragile

Some items can survive a bumpy ride. Others can’t. Fragile items are the ones that need extra care when shipping.

These are things that break, crack, or get damaged easily — like glassware, ceramics, electronics, or anything with delicate parts. Even small pressure, sharp turns, or drops during delivery can cause damage.

What makes something fragile isn’t just the material. Shape and weight matter too.

Thin parts are more likely to snap.
Heavy items can crush what’s packed next to them.
Odd shapes may shift around inside the box if not packed well.

Many industries deal with this every day.

If you ship beauty products, home decor, small appliances, or food in glass jars, you’re already familiar with the risks. Even a well-made product can break without the right protection.

That’s why packaging and handling are so important.

Once a product leaves your hands, you can’t control what happens. But if it’s packed right, it’ll have a much better chance of making it in one piece.

The rest of this guide will show you how to ship fragile items.

Choose the right packaging materials

The first thing you need to think about is the material. Not all boxes or fillers are made for fragile items.

Double-wall boxes are one of the best choices.

They have two layers of corrugated board instead of one. That gives them more strength and better protection against impact. If you’re shipping something heavy or breakable, use a double-wall box instead of a single-wall one.

Now let’s talk about what goes inside the box.

You need to fill the empty space around the product. This keeps it from moving during transit. Some good options:

Bubble wrap
Foam padding
Crumpled kraft paper

Each material works a bit differently. Bubble wrap is great for wrapping individual items. Foam offers strong cushioning. Paper fills empty space quickly and is more eco-friendly.

If your product is oddly shaped or delicate, consider a custom insert. Foam inserts hold your product snug and reduce movement. You can learn more here:

👉 Foam Inserts

Paperboard inserts or dividers work well for things like cosmetics or candles. They’re sturdy and can be cut to fit your product exactly. Here’s an example:

👉 Box Inserts

You don’t always need expensive packaging—but you do need the right one. The goal is to keep your product still and protected. That’s what good materials help you do.

Pick the right box

Your box is the first line of defense. If it’s too big or too weak, your fragile item won’t make it safely.

Start with the right size. Too much space inside means the item can move and get damaged. Too little space leaves no room for padding. A good rule is to add 2–3 inches around the product for cushioning.

Now look at strength. Use the box’s ECT (Edge Crush Test) and burst strength to choose the right one. Here’s a quick guide:

Box Types	ECT Rating	Burst Strength	Max Weight	Best For
Standard	ECT 32	200 lb/in²	Up to 30 lb	Light goods, local shipping
Medium Duty	ECT 44	275 lb/in²	Up to 50 lb	Fragile items, medium loads
Heavy Duty	ECT 48+	350 lb/in²	50 lb+	Heavy or high-value shipments

Double-wall boxes give you even more protection. They’re great for fragile items, especially during long-distance shipping.

Don’t overpack. Too much weight can crush the box or damage what’s inside. Follow the box limits and pack items evenly to keep everything safe.

A strong, well-sized box is the basis of safe shipping for fragile items. Get this step right, and the rest will be much easier.

How to pack

Once you’ve got the right box, the next step is what goes inside. This is what keeps your fragile item from shifting, cracking, or breaking during shipping.

Start by packing the product itself. Use soft, shock-absorbing materials like bubble wrap, foam sheets, or padded paper. Wrap tightly, but don’t press too hard—just enough to cover every surface and corner.

If your item has a weird shape—like a handle, spout, or thin edge — pay extra attention to those spots. Add more padding where the item is most likely to crack or bend.

After wrapping, place it in the center of the box. Don’t let it touch the walls. You want at least 2 inches of space on all sides.

Now fill the space around it. This step stops the item from moving. You can use:

Foam padding
Crumpled kraft paper
Air pillows
Custom-shaped inserts (for products with specific dimensions)

Custom foam inserts work great for electronics, glassware, and other delicate shapes. They hold your product in place and absorb shock better than loose fill.

The goal is to make sure the item doesn’t move — even if someone shakes the box. If you hear anything rattle, add more padding.

Done right, wrapping and cushioning protect the product no matter how it’s handled.

Seal and label like a pro

Even if you pack everything right, the box still needs to be sealed and labeled correctly. This helps protect the product and guides the shipping process.

Start with the tape. Always use strong packing tape—at least 2 inches wide. Don’t use duct tape, masking tape, or anything meant for home use. They don’t stick well and can peel off during transit.

Use the “H-taping” method:

One strip down the center seam
One strip along each edge where the flaps meet

This seals the top and bottom securely. Press the tape down firmly and make sure it covers all seams.

Now let’s talk about labels.

“Fragile” and “This Way Up” stickers help handlers know how to treat the box. They’re not perfect, but they still reduce the chance of rough handling. Place them on multiple sides—top, front, and back.

Also make sure your shipping label is easy to read and placed flat on the box. Wrinkled or half-peeled labels can cause delivery delays.

Here are a few extra tips:

Put the barcode on a flat surface, away from edges or seams
Avoid placing it over tape or folds
Add a packing slip inside the box and one in a clear pouch outside
If shipping internationally, include customs info in a plastic sleeve

A well-sealed, clearly labeled box tells the carrier: “Handle this with care.” And that small effort goes a long way.

Avoid common packing mistakes

Even if you have good materials, one small mistake can still lead to damage. These are the most common packing errors—and how to avoid them.

Overpacking the box

It might seem like a tight fit is safer, but stuffing too much into a box puts pressure on the items and the box walls. This can cause the box to burst or the items to crack under pressure. Always follow the weight limit printed on the box.

Reusing old or weak boxes

Recycled boxes may look fine, but the structure gets weaker each time it’s used. If the corners are soft or the flaps don’t close flat, it’s time to toss it. Use a fresh, strong box—especially for anything fragile.

Using the wrong tape

Not all tape is made for shipping. Avoid masking tape, scotch tape, or painter’s tape. They don’t hold under pressure or during temperature changes. Stick with pressure-sensitive packing tape, at least 2 inches wide.

Skipping padding or leaving empty space

When items can move inside the box, they’re more likely to break. Always fill gaps around the product with foam, paper, or other void fillers. The item should feel secure and snug inside.

These small mistakes cost money, damage your brand, and lead to returns. Taking the time to avoid them will make your shipping process more reliable — and save you trouble down the line.

Shipping methods and carrier options

Once your fragile item is packed, the next big decision is how to ship it—and who to trust with it.

Not all shipping methods treat packages the same way. Standard ground shipping is fine for sturdy items. But fragile goods often need more care.

If the item is valuable or breakable, consider options like:

Expedited shipping: Less time in transit means less handling and fewer chances to get damaged
White-glove service: Ideal for very delicate or high-value goods—includes careful handling and often personal delivery

Now let’s compare 3 common carriers:

Carrier	Strengths	Weaknesses
UPS	Strong tracking, reliable handling	Slightly higher cost for fragile item insurance
FedEx	Fast, good for time-sensitive goods	Handling may vary by location
USPS	Cost-effective for small/light items	Rougher handling, less ideal for fragile goods

Each carrier has different policies for fragile items. Some charge extra for special handling. Others may limit coverage if packaging doesn’t meet their standards. Always check their terms before shipping and find the best company for you.

Also think about distance. Local deliveries may do fine with regular service. International shipments may need more protection and insurance.

Choosing the right shipping method can make or break your delivery—literally. Match the method to the product’s fragility, weight, and value. It’s worth the extra thought.

Insurance and tracking for peace of mind

Even with the best packaging and shipping method, things can still go wrong. That’s where insurance and tracking come in.

Shipping insurance helps cover the cost if your package is lost or damaged in transit. Most major carriers offer it, but you may need to add it during checkout. The cost depends on the item’s value.

Always check what the insurance actually covers.

Some policies require proof of how you packed the item. That’s why using proper materials—like a strong box and enough padding—is so important.

What if your item arrives damaged?

First, take clear photos of the box and the damaged product. Keep the packaging. Then file a claim with the carrier.

But if you’re using our packaging boxes, don’t worry. If the damage isn’t caused by rough handling, we’ll take full responsibility. That means a free replacement—no questions asked.

Tracking helps prevent problems too.

Make sure you always get a tracking number when shipping fragile items. It lets you and your customer follow the package in real time. If it’s delayed or scanned in the wrong place, you’ll know right away.

And here’s a simple tip:

Take a photo of the packed box before you ship it. It’s a quick way to show how well it was packed, just in case there’s a claim later.

Together, insurance and tracking give you confidence. They protect your product and your business.

Final checklist before you ship

Before sealing the box and handing it off to the carrier, take a moment to double-check everything. This last step can save you from returns, refunds, and angry customers.

Here’s a quick checklist to follow:

Is the box strong enough for the item’s weight?
Did you leave 2–3 inches of padding around the product?
Is the item wrapped tightly with no room to move?
Are there any sharp edges or corners that need extra cushioning?
Did you fill all empty space inside the box?
Is the box sealed using the H-taping method with strong packing tape?
Are the shipping labels flat, clear, and easy to scan?
Did you add “Fragile” or “This Way Up” labels if needed?
Did you include the correct packing slip or customs form?
Did you get a tracking number?

Also, inspect the box like a customer would. Ask yourself, “Would I feel confident receiving this package?” If not, fix it now before it leaves your hands.

If your team handles packing, make sure they’re trained on all the steps above.

Consistency is key—every box should meet the same standard.

Remember, fragile items don’t forgive mistakes. One small issue can lead to a broken product and a lost customer. That’s why this guide exists—to help you prevent that from happening.

Need help finding the right packaging for fragile products? XiangGe Package has helped over 100 brands ship with confidence. Reach out to us for custom solutions that fit your product and budget.

Tag Post :