The Complete Guide to Packaging for Air Freight Shipments

Air freight is the fastest way to ship goods worldwide. With airlines operating thousands of flights per day, goods can be transported across continents in just hours. This makes air cargo ideal for time-sensitive shipments like perishable foods, medical supplies, electronics, and other high-value items. However, the advantages of air shipping come with strict packaging requirements. Aircraft space is limited, so packages must be compact and structurally sound. Goods must also withstand pressure and temperature changes during flight.

Following air cargo packaging protocols isn’t just about protecting your shipment – it’s also legally required by airlines and aviation authorities around the world. Noncompliant packages may be refused for air transport to maintain safety and security standards. In this article, we’ll cover everything you need to know about packaging for air freight shipments.

Importance of Proper Air Cargo Packaging

While air freight is generally a smoother ride than ground or ocean shipping, shipments still face risks like turbulence, pressure changes, temperature fluctuations, and potential mishandling. Sturdy, secure packaging protects your goods from these hazards. It also complies with airline regulations and prevents issues like crushed boxes or rattling contents that could raise security concerns.

Air Freight Packing Materials

The right materials are key for safe air cargo packaging. Here are some essentials:

• Outer Containers: Use double-walled corrugated fiberboard boxes rated at least 200 lbs per square inch (PSI) combined edge crush test (ECT). Avoid using boxes that could fail.
• Inner Cushioning: Bubble wrap, air pillows, foam peanuts, and crumpled kraft paper provide impact protection.
• Reinforcements: Crates, plywood sheets, edge protectors, and double-boxing help reinforce and immobilise contents for heavy shipments.
• Securing: Plastic pallet sheets, stretch wrap, strapping or banding keep palletised/skidded freight unitised.

Special containers like insulated boxes are required for temperature-sensitive items like perishable foods or pharmaceuticals.

Step-by-Step Packing Process

Follow this process to properly package air freight shipments:

1. Choose the right outer box and cushion contents with internal packaging. Use double-walled corrugated boxes rated for 200 lbs/sq.inch crush test. Line with bubble wrap, foam peanuts, or air pillows to cushion contents.
2. Securely close and seal boxes with reinforced water-activated tape or hot melt adhesive. Apply at least three strips per box seam.
3. Mark all boxes with shipping names/addresses, UN numbers for hazardous goods, orientation arrows, and handling instructions like “Fragile” or “This Side Up.”
4. For palletised freight, position heavier boxes/crates at the pallet base, working upwards with lighter boxes on top. Using skids also eases ground handling.
5. Secure freight to the pallet securely with ample stretch wrap, plastic banding, or netting to create a stable unitised load.
6. Properly label and mark palletised shipments per airline requirements. This includes address labels, hazmat markers, gross/net weight, and dimensions.
7. Include proper documentation like air waybills, packing slips, and any permits for controlled items.
8. Use the required internal packaging for any temperature-sensitive, perishable, or hazardous materials shipments per regulations.

Following this systematic process ensures air freight is properly immobilised, cushioned, secured, and compliant with all packing protocols. This prevents damages and delays.

How Is Air Freight Size Calculated?

Freight rates and Fuel surcharges are calculated on the chargeable Weight Storage and other charges are calculated on the gross weight (unless otherwise mentioned).

Here’s how it works:

Volumetric Weight

• (LxWxH) in Cms / 6000

Chargeable Weight:

• Gross Weight or the Volumetric Weight, whichever is the highest will be the chargeable weight

CBM

• Volumtric weight / 166.66 

Larger/Irregularly Shaped Freight

• For air freight shipments on skids or crates, the calculations are similar but measure the entirety of the secured load as one unit. Dimensional weight ensures charges account for the container’s total cubic space.
• Airlines want to maximise the use of their cargo hold space, so volumetric pricing ensures appropriate fees for bulky yet lightweight shipments. Proper packaging to minimise wasted space can reduce dimensional weight charges.

Size and Weight Restrictions

Air cargo is limited by both maximum weight and dimensions due to aircraft capacity and operational constraints. Most airlines restrict:

• Length: 150 inches (381 cm) max
• Width: 118 inches (300 cm) max
• Height: 100 inches (254 cm) max
• Total linear dimensions: 292 inches (742 cm) max

Weight limits vary by aircraft and routing, but shipments over 150 lbs typically require palletisation or skidding. There are no stated minimum size limits, but small shipments may incur surcharges.

Pricing is based on the greater of actual weight or calculated dimensional weight. Dim weight pricing penalises oversized, light shipments to account for the space they occupy.

Prohibited, Restricted, and Regulated Items

Many goods are regulated or banned from air transport due to potential hazards. Shippers must be aware of restrictions and pack permitted dangerous goods very carefully.

Dangerous Goods

Flammable, corrosive, explosive, toxic, or radioactive materials are classified as dangerous goods tightly regulated for air transport. Common examples include gasoline, fireworks, acids, compressed gases, and radioactive medicines. These items require UN-certified packaging, hazard labels, and proper documentation.

Lithium Batteries

Power source risks make lithium batteries a regulated commodity. They must have adequate circuit protection and be shipped at less than 50% charge level. Damaged batteries are prohibited. Compliant packaging and separate handling are mandatory.

Some Perishables

Certain fresh foods may be restricted due to odours that could distract flight crews or natural gas emission risks. Items like durians, blue cheese, and some meats could get banned depending on the airline.

Other Restricted Cargo

Airlines cap quantity or prohibit items that could leak, contaminate, attract pests, or introduce illegal substances and agriculture. This includes things like lawn fertilisers, seeds, soil, live animals, and hemp/cannabis products.

Always check for specific commodity restrictions with your air carrier before shipping. Properly package any permitted dangerous goods per hazmat regulations using UN-rated containers and labelling. Misrepresenting contents or improper packing could lead to steep penalties.

Documentation and Labeling

In addition to sturdy packaging, shipments require proper documentation and handling labels, including:

• Air Waybill (AWB): The contract of carriage with details like weights, counts, and descriptions.
• Packing List: Itemised contents of each piece in the shipment.
• Handling Labels: Orientation arrows, hazard warnings, name/address, and more.
• Security Declarations: Certifying screening and packaging integrity.

Final Thoughts

By following airline requirements for packaging, labelling, and documentation, you ensure your air freight shipments are accepted and transported quickly and safely to their final destinations worldwide. With the right preparation, air shipping can seamlessly move your cargo across the globe.