Amazon FBA Box Size Requirements & Weight Limits

Amazon FBA Box Size Rules That Can Make or Break Your Profits

Successfully selling on Amazon FBA depends on understanding the intricate details of their shipping requirements. 

Amazon FBA sellers know that small details make the difference between profit and frustration. Box size requirements might seem like a standard logistical concern, but they directly impact your bottom line through shipping costs, handling fees, and even your account's good standing. 

The recent updates to Amazon's FBA box size requirements have opened new opportunities for sellers with longer products while maintaining strict guidelines on other dimensions. Understanding these specifications helps you avoid costly rejections or repackaging fees.

Standard Amazon FBA Box Size Requirements

Length Limit: Recent Update from 63.5 cm to 91.4 cm

Starting June 20, 2025, Amazon increased the maximum allowable box length for FBA shipments from 63.5 cm to 91.4 cm. This adjustment provides welcome relief for sellers of longer products who previously had to split items across multiple boxes or resort to less efficient packaging methods. 

The change has been useful for categories like sporting goods, home decor, and automotive parts, where longer items are standard. Sellers report reduced packaging costs and simpler preparation procedures since implementing the new guidelines.

Width and Height Requirements: Still Capped at 63.5 cm

Despite the increased length allowance, Amazon has maintained its 25-inch maximum for both width and height dimensions. This limitation reflects warehouse shelving configurations and conveyor belt specifications throughout the fulfilment network. 

Exceeding these dimensions automatically classifies your shipment as oversized, potentially triggering higher handling fees and special processing requirements. The 25-inch cap on width and height applies to all product categories and seller levels.

Amazon's automated receiving systems are calibrated to these specifications so that non-compliant boxes may face processing delays or even rejection. For products that naturally exceed these dimensions, sellers should explore Amazon's oversized product handling options rather than force-fitting items into non-compliant packaging.

Minimum Box Dimensions: 15.2 x 10.1 x 2.5 cm

While most sellers focus on maximum size limitations, Amazon also specifies minimum box dimensions of 15.2 x 10.1 x 2.5 cm. These minimum requirements ensure that packages don't get lost in Amazon's vast fulfilment centres or slip through automated sorting equipment. 

Packages smaller than these dimensions are at risk of delayed processing, misplacement within the warehouse, or damage during transit between sorting stations. Amazon specifically notes that boxes meeting or exceeding these minimum dimensions and weighing at least 450g experience fewer receiving delays. 

This is key during peak seasons when fulfilment centres process millions of packages daily. Small boxes that don't meet these minimum requirements may be grouped with other shipments or face manual processing, which can add unpredictable delays to your inventory availability.

Maximum Box Weight Limits

Standard Package Maximum: 22.6 kg

The 22.6 kg maximum weight limit for standard FBA boxes represents a hard ceiling for most shipments. Exceeding this weight limit without proper exception handling may result in the immediate rejection of your shipment. 

Many sellers mistakenly assume larger boxes can accommodate heavier weights, but Amazon's automated conveyor systems and manual handling processes are optimised for this specific weight threshold.

Approaching but not exceeding this weight limit often makes economic sense, as it allows you to maximise the value of each shipping unit. Efficiently packing products together within the weight constraint can significantly reduce your per-unit fulfilment costs. 

Oversized Item Exception Rules

The only scenario in which exceeding the standard weight limitations is acceptable is when shipping individual oversized items that inherently exceed these limits. This exception applies specifically to products that cannot be physically reduced to fit within standard constraints-think large televisions, furniture, or heavy appliances. 

When shipping such items, you must clearly indicate on your shipping plan that you're sending an oversized product. For oversized exceptions, Amazon implements a different handling process and fee structure. These items bypass standard conveyor systems and receive specialized handling throughout the fulfilment centre. 

The dimensional weight calculation also differs for oversized items, often resulting in significantly higher fulfilment fees.

Special Labeling Requirements for Heavy Items

Boxes weighing more than 15 kg require 'Heavy Package' labels on the top and sides-these high-visibility warnings alert fulfilment centre associates that the package requires two-person handling to prevent injuries.

The placement of these labels becomes especially critical on heavier packages, as they may undergo different scanning procedures than standard-weight items. 

Standard Amazon FBA Box Construction Requirements

Box Construction Standards: Regular Slotted Cartons (RSC)

Amazon strictly specifies the type of boxes acceptable for FBA shipments. Regular Slotted Cartons (RSC) are the industry standard that Amazon requires. These boxes feature manufacturing specifications that ensure durability throughout the fulfilment process, and the flaps meet in the middle when closed.

The flute designation refers to the corrugated medium between the inner and outer liners, providing the optimal balance of cushioning, stacking strength, and printing surface. Your boxes must meet or exceed the appropriate Edge Crush Test (ECT) rating or have adequate burst strength. 

This isn't arbitrary-these specifications ensure your packages can withstand the mechanical handling, stacking pressure, and potential impact during transit through Amazon's fulfillment network. Using substandard packaging materials risks damage to your products and potential account restrictions.

How to Properly Pack Your FBA Shipments

Proper packing technique is just as important as meeting the dimensional and weight requirements for your FBA shipments. Amazon evaluates not only whether your packages comply with size specifications but also how well the contents are protected and organized. Implementing the following packing fundamentals can significantly reduce product damage rates and speed up the receiving process at fulfilment centres:

• Use appropriate dunnage (packing materials) for fragile items to prevent movement within the box

• Seal all boxes with strong packing tape across all seams (72mm ProLoc recommended)

• Avoid using strapping, string, or excessive tape, as they can interfere with processing

• Include only one shipment ID per box-never combine multiple shipments

• Distribute weight evenly throughout the box to prevent shifting during transit

• Apply box content labels according to the shipment plan instructions

For sellers shipping fragile items, additional internal packaging, such as custom inserts or suspension packaging, may be necessary to meet this standard. Proper documentation is another important aspect of FBA shipment preparation. Each box requires specific paperwork, including packing slips and information about the box contents. 

The Amazon Partnered Carrier program streamlines much of this process, automatically generating compliant documentation when you use their shipping services. For sellers managing their own freight, to guarantee all paperwork meets Amazon's specifications is essential to prevent receiving delays.

Streamline Your Shipping with Globe Packaging

Understanding Amazon's FBA box size requirements is essential for sellers looking to minimise fulfillment costs and avoid costly delays or penalties. At Globe Packaging, we stock a complete range of Amazon FBA-compliant boxes to help UK sellers meet Amazon's strict packaging requirements without the guesswork. 

We have several approved dimensions ranging from standard envelope sizes (33x23x2.5cm) to oversize boxes (120x60x60cm), so that you maximise space efficiency while staying compliant and keeping fulfillment costs as low as possible. 

With next working day delivery on orders placed by 4 PM and competitive bulk pricing, we make it easy to keep your FBA operations running smoothly. Whether you're shipping standard envelopes or oversized items, our team understands the importance of getting your packaging right the first time.

Browse our full range of Amazon FBA boxes at globepackaging.co.uk today! 

Note: Product listings, prices, and delivery times shown are approximate and subject to change. Contact us at Globe Packaging for the latest information.