Why Proper Packaging Matters

A poorly packed package is one of the most common reasons for damaged shipments, delivery delays, and failed claims. USPS handles millions of packages daily — yours needs to withstand sorting machines, multiple handoffs, and stacking. Good packaging isn't just about looks; it's about protection.

Choosing the Right Box

Start with the right container. Here's what to keep in mind:

  • Use a new or sturdy corrugated box whenever possible. Reused boxes can have weakened walls and seams.
  • Choose a snug fit. The box should be large enough to hold your item plus 2 inches of cushioning on all sides.
  • Avoid oversized boxes for small items — they're more likely to be crushed or bent during transit.
  • Free USPS boxes: Priority Mail and Priority Mail Express boxes are available free at your local Post Office or at usps.com. Note: These must only be used for those specific services.

Cushioning and Padding

Cushioning absorbs shock and keeps your item from shifting. Common options include:

  • Bubble wrap: Excellent for fragile or irregularly shaped items.
  • Packing peanuts: Good for filling void space around smaller items.
  • Crumpled kraft paper: An eco-friendly alternative for non-fragile goods.
  • Air pillows: Lightweight and effective for filling empty space.
  • Foam inserts: Ideal for electronics, cameras, or valuable collectibles.

The general rule: shake the box after packing. If you can feel the item moving, add more cushioning.

Sealing Your Package

Proper sealing is just as important as proper packing:

  1. Use pressure-sensitive tape, filament tape, or water-activated tape that is at least 2 inches wide.
  2. Avoid masking tape, cellophane tape, or duct tape — these do not hold up under the stress of postal handling.
  3. Apply the H-tape method: seal the top center seam and both edges perpendicular to it, forming an "H" shape.
  4. Tape over all original seams, especially on reused boxes.

Labeling Your Package Correctly

A lost package is often a mislabeled package. Follow these labeling best practices:

  • Write or print addresses clearly in dark ink on a white or light background.
  • Include both the recipient's full address and your return address.
  • Always include the ZIP+4 code when possible for faster sorting.
  • Place a second address label inside the box — if the outer label gets damaged, your package can still be delivered.
  • Make sure no old labels, barcodes, or addresses are visible on reused boxes.

Special Considerations for Fragile Items

If shipping something breakable:

  • Wrap each piece individually before placing together.
  • Use at least 3 inches of cushioning on all sides.
  • Mark the package "Fragile" — though note this is a courtesy indicator, not a guarantee of special handling.
  • Consider double-boxing: place the item in a smaller well-padded box, then place that inside a larger box with additional padding.

Restricted and Prohibited Items

Before shipping, make sure your item is allowed. USPS prohibits certain goods including:

  • Hazardous materials (flammables, corrosives, explosives)
  • Perishable foods (without special packaging and declarations)
  • Lithium batteries (under specific restrictions)
  • Alcohol and tobacco (domestic restrictions apply)

Visit the USPS Hazardous Materials page or ask at your local Post Office if you're unsure.

Taking a few extra minutes to pack your shipment correctly can save you from costly damage claims, delays, and the headache of a lost package. When in doubt, over-pack rather than under-pack.