If you’re selling through Amazon’s Fulfilment by Amazon (FBA) program in 2025, getting your packaging right isn’t optional it’s an essential part of your operational success. Poor packaging can lead to damaged goods, Amazon receiving refusal, increased fees, or delays. This guide walks you through everything sellers need to know in 2025: from general packaging rules, to product‐type specific requirements, to shipping box & pallet guidelines, to sustainability considerations.

Why Packaging Matters for FBA Sellers

Before we dive into the rules, let’s quickly underline why packaging is so important:

• Amazon expects quality packaging as part of its customer-experience promise.

• Mistakes can lead to: items being rejected at the fulfilment centre, extra prep fees, delays in your stock going live, or increased damage returns.

• Proper packaging helps protect your brand: fewer complaints, fewer “received damaged” returns, better reviews.

• Also: packaging influences your shipping/fulfilment cost smaller, lighter, well‐packed units cost less.
  As one resource notes: “Boxes must be sized correctly and weight limits followed to avoid extra fees or restrictions.”

So let’s get to it.

1. General Packaging Requirements for FBA Shipments

These are the broad “must-do” rules that apply to almost every product you send into Amazon’s fulfilment centres:

1.1 Box size & weight limits

• Standard boxes sent to Amazon should not exceed 25 inches on any side unless you are dealing with an oversize item.

• Maximum box weight is typically 50 lbs (approx. 22.7 kg) for a standard box.

• If you have an oversize item (where a single unit exceeds these limits) Amazon allows exceptions but the box you choose must not be overly large relative to the item, or you may face delays or fees.

1.2 Box construction & condition

• Use new (or like‐new) corrugated cardboard boxes. Previous use boxes must be fully cleared of old labels/barcodes.

• Boxes must have six sides, the opening must not easily open on its own, and the box must not collapse when moderate pressure is applied to any side.

• Boxes reused must have old labels/barcodes obscured or removed to prevent mis‐scanning.

1.3 Labeling requirements

• Each shipping box must carry a unique “FBA Box ID” label (generated from your shipping plan) so Amazon can track its contents.

• If you’re shipping pallets, each pallet must have four pallet ID labels (one on each side).

• On individual units sent into FBA, each unit must have a scannable barcode (e.g., UPC, EAN or Amazon’s FNSKU) affixed correctly.

1.4 Internal packing & cushioning

• You must cushion items inside the box well so they don’t shift and get damaged. Many guides recommend at least 2 inches of cushioning around the product.

• Prohibited or discouraged packing materials include shredded paper, unstable packing peanuts, loose fill that can move easily.

1.5 Shipping plan and box content info

• Before sending shipment to Amazon, you must provide accurate box content information via the shipping plan (e.g., how many units inside each box) in Seller Central.

• Mis‐reporting box dimensions, weight or contents can lead to receiving delays, extra fees or refusal.

2. Packaging Requirements by Product Type

Certain product types carry extra rules. Here are key special cases to highlight:

2.1 Poly-bagged units

If your product is bagged rather than boxed (for example clothing, textiles, some soft goods):

• Polybags must be at least 1.5 mil thick (i.e., 0.0015 inches).

• For polybags with a 5-inch (approx. 12.7 cm) opening or larger, a “suffocation warning” must be printed or attached.

• The polybag must be transparent (unless adult/other special category) so barcode is scannable through it.

• The polybag or shrink wrap must not protrude more than 3 inches beyond the product dimensions.

• Adult products must use opaque or black bags (not transparent) for privacy/sensitivity.

2.2 Loose products / non-boxed units

If the unit is loose (no box, open product) you must secure it:

• Either bag it or wrap it with removable tape so the product is contained.

• Barcode must be scannable without having to open the bag or unwrap it.

2.3 Products sold as a “set”

If you are selling multiple items together as a single unit:

• Clearly label the packaging with statement such as “Sold as set,” “This is a set. Do not separate,” etc.

• The set must have its own unique FNSKU (barcode) rather than using individual unit barcodes alone.

2.4 Fragile / glass / heavy / sharp / liquid & hazardous goods

• Fragile items (glass jars, ceramics, electronics) must be packaged with extra protection (bubble wrap, heavy-duty box) and should pass drop tests (often a 3-foot drop test) to ensure viability.

• Liquids must be sealed to prevent leakage and often must be placed in poly bags with suffocation warning and additional sealing.

• For sharp objects or items posing risk, Amazon’s newer “Ships in Product Packaging” (SIPP) certification guidelines specify what counts as “sensitive” and how to test.

2.5 Oversize items

If you’re sending items where a single unit is oversize (ex: longer than 25 inches side, or heavier than 50 lbs) then the “standard box” rules might not apply.

• But you must still ensure the box isn’t excessively larger than the item (to avoid wasted space, shifting & damage).

• For heavy boxes (over 50 lbs) you may need “Team Lift” or “Mechanical Lift” labels for safety and compliance.

3. Shipping Box & Pallet Requirements for Inbound to Amazon

When you’re preparing a shipment to send into Amazon’s fulfilment centres (inbound), you must conform to these additional packaging & routing rules.

3.1 Box-level requirements

• Each box must have one unique Amazon Box ID label (printed via your shipping plan).

• The box should have a single address label with complete delivery & return information.

• Remove or cover old shipping labels/barcodes (if re‐using a box) so old codes are not scanned and confuse the intake process.

• For small parcel delivery (SPD) shipments, each box should meet the standard size/weight limits (25″ max each side, 50 lbs max) unless item is oversize.

3.2 Pallet / LTL / FTL shipments

• If you ship on pallets, wrap the pallet securely, ensure the boxes are square and stable, and affix four FBA Pallet ID labels (one each side).

• Work with Amazon’s carrier partners or approved carriers and ensure the pallet meets Amazon’s “Shipping & Routing Requirements”.

• Make sure the pallet is configured so that boxes can be picked/moved easily without damage or instability.

3.3 Miscellaneous tips

• Provide accurate box dimensions and weights in your shipping plan inaccurate weights/dimensions can lead to re‐weighing, delays or extra fees.

• Use strong tape (typically 2-3 inch wide packing tape) on all seams and edges to prevent box opening in transit.

• Use cushioning so items don’t shift inside the box; minimal shifting = less chance of damage and returns.

4. Labeling & Barcodes: What You Must Know

Labeling is not just an afterthought correct barcodes and label placement are crucial.

4.1 Unit labeling

• Each unit must have a scannable barcode that links it to your offering (UPC/EAN or Amazon’s FNSKU). Amazon uses this to track inventory at the fulfilment centre.

• If you choose to use UPCs instead of FNSKU, be aware Amazon may commingle inventory with other sellers using the same UPC. If you want exclusive inventory control, use FNSKU.

• The barcode must be on a flat surface and easily accessible (not on a fold, seam or inside a polybag where it cannot be scanned).

4.2 Shipping box labels

• FBA Box ID label: each shipping box from your plan must have this. It includes a barcode and human‐readable number.

• Carrier label: for standard carriers (e.g., UPS, FedEx) you must attach the shipping/courier label too.

• Label placement: place labels on a flat surface of the box, away from seams or edges. Avoid overlapping two labels.

• For pallets, each of the four sides needs a Pallet ID label.

4.3 Important barcode/label – “Do not scan old codes”

• If reusing boxes, cover or remove any old barcodes so Amazon doesn’t inadvertently scan the wrong one.

• For polybags or bundled units, ensure the barcode on the outside is visible and scannable without removing the bag or packaging.

5. Sustainability & Branding: What’s Trending in 2025

While compliance is mandatory, packaging strategy in 2025 also includes branding and sustainability considerations. These can help differentiate your brand and reduce costs.

• Ships in Product Packaging (SIPP): Amazon’s program for sellers whose products ship in their own product packaging (i.e., minimal extra Amazon packaging) to reduce waste and lower fulfilment costs.

  • SIPP includes “Rigid” and “Flexible” packaging classifications.

  • If you enrol, you can reduce fulfilment fees and offer custom packaging/unboxing experiences.

• Environmental brand image: Many buyers now favour brands that use less plastic, recyclable materials, or minimalistic packaging. As one source notes: “More than 60% of buyers are willing to pay more for products from brands that use environmentally friendly packaging.”

• Efficient packaging = lower shipping & fulfilment cost: Reducing wastes (air space in box, packaging weight) helps you optimise cost. For example, using appropriately sized box rather than oversized one.

• Keep ahead of Amazon’s own changes: The SIPP document states that as of April 2025 new packaging dimension clarifications were introduced.

6. Common Mistakes FBA Sellers Make & How to Avoid Them

Here are frequent packaging errors and how you can avoid them:

• Using a box that is too big: if your item is small but you use a large box, the product can shift, higher risk of damage, extra cost in Amazon receiving. Fix: select a box just slightly larger than the product plus cushioning.

• Box weight or dimensions misreported: if you declare wrong dimensions/weight, Amazon may re‐weigh or re‐measure and you may face fees or rejection. Fix: measure and weigh each box accurately before shipping.

• Old barcodes not removed: re‐used boxes still have old shipping labels or barcodes; Amazon may scan the wrong one and mis‐route your shipment. Fix: cover or remove previous labels completely.

• Polybag without suffocation warning: especially for bags with 5 inch or larger openings, missing this warning can cause items to be re-bagged by Amazon. Fix: ensure the printed warning meets size‐requirements.

• Barcode not visible/scannable: if the unit barcode is hidden under tape, inside a bag that isn’t transparent, or not on a flat surface delays will occur. Fix: check visibility and barcode placement.

• No cushioning for fragile items: glass, ceramics or products with many parts need extra protection. Fix: double‐box if needed, add bubble wrap or air pillows, do a drop‐test yourself.

• Using prohibited packing materials: shredded paper, foam strips that can compress too much, unstable fill — these are risky. Fix: use air pillows, bubble wrap, kraft paper, as recommended.

7. Checklist for 2025 Sellers Before You Ship

Use this quick checklist to ensure your packaging and shipment to FBA is buttoned up:

• Unit level: correct scannable barcode (UPC/EAN or FNSKU) applied and visible.

• Unit packaging: bag or box as required (polybag thickness, suffocation warning if polybag).

• Box: new or good condition, six-sided, no collapse when pressed, dimensions within limits (≤25 in each side unless oversize).

• Box: accurate weight recorded and dimensions measured.

• Cushioning: items secured and won’t shift inside the box.

• Labels: FBA Box ID label applied on flat surface, carrier label also applied.

• If re-using box: remove/cover old labels/barcodes.

• If pallet: secure pallet, four pallet ID labels, stable stacking.

• Within shipping plan: correct box content information (how many units, SKU, etc).

• For sets: “Sold as set” label and unique FNSKU for the set.

• For special categories (fragile, liquids, adult): ensure additional packaging/sealing as per the rules.

• Consider sustainability / branding: is packaging optimized (size, weight, materials)? Are you eligible / considering SIPP?

• Double-check Amazon’s latest help pages rules do change. For example, the SIPP guidelines updated in April 2025.

8. Final Thoughts & Next Steps

Getting your packaging right for Amazon FBA in 2025 is a critical part of running a successful e-commerce business. By following Amazon’s explicit requirements and adopting best practices for protection, efficiency and sustainability, you’ll reduce risk, control cost and provide a better experience to customers.

Here are your next steps:

1. Review all of your current SKUs and map out which ones may have special requirements (fragile, liquid, polybag, set).

2. Audit your packaging materials and processes (boxing, labelling, cushioning).

3. Create a checklist or SOP for your team or supplier to ensure compliance.

4. If you are shipping from overseas (e.g., manufacturing in Asia) make sure your supplier understands the Amazon packaging rules and you can inspect before shipment.

5. Monitor for any changes in Amazon’s policies. Amazon frequently updates Help & Policies pages and its programmes (e.g., SIPP).

6. Consider packaging optimisation: downsizing box, reducing weight, using sustainable materials this can reduce your shipping/fulfilment cost and create brand advantage.

Conclusion

Packaging might seem like a small operational detail, but in Amazon FBA, it’s one of the biggest factors that determines whether your business runs smoothly or constantly faces setbacks. In 2025, Amazon’s fulfillment standards have become stricter than ever and sellers who don’t comply risk delays, added fees, or suspended shipments.

By mastering the Amazon FBA packaging requirements, you’re not just protecting your products you’re protecting your brand’s reputation, improving delivery efficiency, and enhancing customer trust. From choosing the right box size and cushioning materials to following Amazon’s labeling, barcode, and sustainability guidelines, every step contributes to a more profitable and compliant operation.

Smart sellers treat packaging as a strategic advantage optimizing it for cost, protection, and eco-friendliness. As Amazon continues its push toward sustainable fulfillment, adapting early will put your brand ahead of the curve.

So before sending your next shipment, revisit your packaging SOP, update your labeling templates, and ensure your team (or 3PL) follows this 2025 checklist precisely. When your packaging meets Amazon’s exact standards, your products reach customers faster, safer, and with the professional presentation your brand deserves.