When it comes to reliable domestic and international delivery, shipping with FedEx Australia is a go-to choice for many businesses. At eBPak, we work with brands across Australia to streamline fulfilment, and one thing we know for sure? Great shipping starts with great preparation.
If you’re new to FedEx or just want to make sure you’re ticking every box, this guide walks you through essential FedEx shipping preparation, best packaging practices, and key FedEx parcel requirements, to help your shipments arrive safely and on time.
Understanding FedEx Shipping Requirements in Australia
Before sending anything, it’s important to understand the general FedEx shipping requirements Australian businesses must follow.
FedEx allows customers to use either official FedEx packaging (for Express services) or their own sturdy outer packaging. If you’re using your own box, it must be:
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Strong and undamaged.
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Made of corrugated fibreboard.
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Free from holes, tears or corner dents.
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Cleared of old shipping labels.
Chipboard boxes (like shoe or gift boxes) should always be placed inside a proper outer corrugated carton. Heavier shipments benefit from double-wall boxes for added strength.
If your packaging doesn’t fully enclose the contents in a protective outer container, you may incur additional handling surcharges. That’s why proper preparation isn’t just about safety; it can also protect your bottom line.
Size and Weight Guidelines: Size Matters
One of the most important FedEx parcel requirements involves size and weight limits.
For standard parcel services (including Express and Ground equivalents), packages can generally weigh up to 68kg (150 lbs). Length and girth restrictions also apply.
Length and girth is calculated as:
Length + (2 × Width) + (2 × Height)
If your shipment is large but lightweight, dimensional weight may apply. This means shipping costs could be calculated based on volume rather than actual weight.
For multi-piece shipments that exceed 68kg combined, freight services may be a more appropriate option.
If you’re unsure whether your shipment qualifies, it’s always better to measure carefully and confirm before booking.
FedEx Shipping Preparation: Packing Methods That Work
Strong packaging is the backbone of safe delivery. FedEx provides two common packing methods depending on what you’re shipping.
1. Single-Box Packing Method
This method is best for packing non-fragile items like soft goods or apparel, or for general items that do not require extra protection. Here’s how to do it properly:
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Use a sturdy outer box.
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Fill empty spaces with cushioning material (air cushioning, crumpled kraft paper, or loose-fill packing material).
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Seal the box using the H taping method.
The H taping method involves sealing all seams on the top and bottom of the box, creating an “H” shape with strong packing tape, such as pressure-sensitive plastic tape or water-activated reinforced tape (minimum 2 inches wide). Avoid duct tape, masking tape, string, or rope.
Movement inside the box is one of the most common causes of damage. Proper cushioning prevents items from shifting in transit, reducing the likelihood of damaged goods.
2. Box-in-Box Packing Method
For fragile or high-value items, double boxing is strongly recommended. This method would include:
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Wrap each item individually in at least 5cm (2 inches) of cushioning.
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Place the wrapped item inside a smaller corrugated box.
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Fill all void spaces to prevent movement.
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Seal the inner box using the H taping method.
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Place that box into a second outer box that’s at least 15cm (6 inches) larger on all sides.
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Add at least 8cm (3 inches) of cushioning between the inner and outer box.
This method significantly reduces the risk of breakage and is considered best practice for electronics, glassware, and delicate goods.
Sealing and Labelling: Small Details, Big Impact
Even the strongest box won’t help if it’s sealed incorrectly. Approved sealing materials include:
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Pressure-sensitive plastic tape
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Water-activated paper tape (minimum 27kg grade)
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Water-activated reinforced tape (minimum 2 inches wide)
Avoid shrink wrap, stretch wrap, or bubble wrap on the exterior of small parcel packages. These materials can interfere with processing equipment.
When labelling your shipment:
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Place the shipping label on top of the box so that it is clearly visible.
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Do not wrap labels around edges or corners.
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Avoid covering barcodes with tape or plastic.
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Remove all old labels.
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Include sender and recipient contact details inside the package as backup.
These steps reduce delays and improve scan accuracy throughout the shipping journey.
Using Polybags: When They’re Appropriate
Polybags or soft mailers, such as our popular self sealing Poly Bubble Mailer G1 01 160 x 230mm C5 Black or our best selling Poly Mailer 255mm x 330mm 02 Mailing Satchel White, are commonly used for clothing and non-fragile items. However, there are important FedEx parcel requirements when using them.
Best practice guidelines include:
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Minimum packaging thickness of 3mm.
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Recommended size under 48cm × 33cm × 13cm.
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Not suitable for fragile goods, electronics, liquids, or glass.
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Not recommended for shipments over 2.3kg.
Shipping Specialty or Unique Items
On top of utilising protective packaging materials, some items require extra attention. For example:
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Liquids should be packed upright with secure inner seals and leak-proof internal packaging.
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Rolled goods should be placed in tubes or corrugated cartons.
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Printed matter should be bundled tightly and cushioned inside a double-walled box.
If your shipment includes potentially hazardous or regulated materials, additional documentation and compliance with air transport regulations may apply. In those cases, it’s critical to confirm requirements before dispatch.
Multiple-Piece Shipments
If you need several packages to arrive together, consider:
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The overbox method (placing multiple smaller packages inside one larger outer carton).
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Confirming combined weight and size limits.
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Exploring freight services if total weight exceeds standard parcel thresholds.
Coordinating multiple pieces correctly helps avoid partial deliveries and keeps your fulfilment operations running smoothly.
Why Proper Preparation Matters
Cutting corners in packaging can lead to:
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Damaged goods.
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Delivery delays.
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Additional handling surcharges.
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Customer dissatisfaction.
Proper FedEx shipping preparation protects both your products and your brand reputation. For Australian businesses competing in fast-moving eCommerce environments, reliable shipping is expected, so it's important to meet those standards and expectations at the very least.
At eBPak, we often see that the most successful businesses are the ones that treat packaging as part of their customer experience and business strategy, not just an afterthought.
Ready to Simplify Your Shipping?
If you’re unsure about FedEx parcel requirements, packaging standards or want expert support in optimising your shipping processes, you don’t have to figure it out alone.
At eBPak, we help Australian businesses streamline logistics, packaging, and shipping with FedEx Australia to ensure shipments move efficiently through the network and reach their destination in excellent condition.
Get in touch with our team today to discover how we can optimise your fulfilment operations, ensure every parcel leaves your warehouse compliant and professionally packed, and give you complete confidence in your shipping processes from start to finish.