Knowing how to package parcels comes down to five steps. Choose a sturdy box that fits, cushion the contents, seal every seam, label it clearly and declare anything dangerous. Done well, your parcel is far more likely to arrive intact and at the right door.
Choose the right box or satchel
Match the packaging to the item’s size, weight and shape. Too big and things slide around. Too small and the seams strain, with no room for padding.
- Use a new, sturdy carton where you can. DHL’s packing advice suggests avoiding old boxes, which may have lost their rigidity. It recommends double-wall cartons for fragile or heavy items.
- Check any reused box carefully. It should have no tears, soft corners or water damage. Remove or cover every old label and barcode.
- Keep satchels for soft, unbreakable items such as clothing. Don’t overfill them, as a stuffed satchel can split.
- Pick the smallest box that still fits the cushioning. Many carriers price large, light parcels by their size. Read what cubic weight is and how it affects your freight cost before you choose a box.
Use this quick guide for common items.
| Item | Best packaging | Extra tip |
|---|---|---|
| Clothing and soft goods | Satchel or small box | Keep the satchel flat, not stuffed |
| Documents and contracts | Strong envelope or document satchel | Add stiff cardboard so they can’t bend |
| Glass, ceramics and electronics | Box-in-box with cushioning | Wrap each piece on its own |
| Heavy items and tools | Double-wall carton | Use extra tape and keep weight low |
| Several cartons for one address | Matching boxes, each labelled | Number them, for example 1 of 3 |
Cushion, fill and seal the box
Fill every gap
Wrap each item separately so nothing knocks together. Fill the empty space with bubble wrap, crumpled paper, air pillows or loose fill. Then shake the box gently. If anything moves, add more.
DHL recommends keeping items at least 6 cm from the outside walls and corners of the box. The Australia Post Parcel and Freight Preparation Guide warns that underfilled boxes often collapse. It also says overfilled boxes and satchels can split.
Seal it with the H-taping method
H-taping seals every seam, not just the middle one. The tape forms a capital H across the top of the box.
- Run one strip of tape along the centre seam where the flaps meet.
- Run a strip across each edge seam at both ends of the box.
- Press the tape firmly so it wraps over the edges and grips the sides.
- Repeat the same pattern on the bottom of the box.
Use strong plastic packing tape, with extra strips on heavy boxes. DHL says to avoid cellophane tape, kraft paper tape and string. Skip ribbons, straps and loose handles, which can catch on sorting machines.
How to package fragile parcels and documents
Fragile items
A fragile sticker won’t protect anything on its own. Australia Post, for example, has no general fragile service, so the packaging does the work. For glass, ceramics, electronics and framed items, use the box-in-box method.
- Wrap each item on its own in bubble wrap or foam.
- Pack it snugly into a small inner box, fill the gaps and seal it.
- Place the inner box in a larger, sturdy outer box with cushioning on every side.
- Seal the outer box with H-taping.
Stand bottles upright and keep heavier pieces at the bottom. Retail display boxes are rarely strong, so treat them as the inner box, never the outer one.
Documents
Send documents in a strong envelope or document satchel, not a thin paper envelope. Slip in a piece of stiff cardboard, or use a rigid mailer, so the papers can’t bend. Keep a copy of signed contracts and other originals before they leave the office.
Label your parcel clearly
A clear label gets the parcel to the right door. It also lets the driver call someone if there’s a problem. Include:
- The recipient’s name, plus the business name if there is one
- The full street address, with unit or level, suburb, state and postcode
- A contact phone number for the recipient
- Your return address and phone number, kept apart from the delivery address
- Any delivery notes, such as ‘Deliver to loading dock’ or ‘Call on arrival’
Use one label and place it on the largest, flattest side. Australia Post’s guide says labels shouldn’t wrap around edges, sit over a flap or seam, or be covered by tape. Remove or cover old labels so only one address shows. Put a spare copy of both addresses inside in case the outer label is damaged.
Dangerous goods: check and declare before you book
Many everyday products are classed as dangerous goods in transport. Australia Post’s dangerous and prohibited items guidance says lithium batteries can pose a fire risk if sent incorrectly. It also lists aerosols and flammable liquids, such as nail polish, paint and perfume, among items that can’t be posted.
Watch for these common items:
- Lithium batteries, power banks and devices with batteries inside
- Aerosols such as deodorant, spray paint and cleaning sprays
- Flammable liquids such as nail polish, perfume, paint and fuel
- Lighters, plus corrosives such as some batteries and chemicals
Rules vary between carriers, and between road and air transport. Some carriers only accept dangerous goods with prior consent, and some won’t carry certain items at all. Tell your courier exactly what is inside when you book, so they can confirm whether and how it can travel.
Not sure if a product counts? Check Section 14 (Transport Information) of its Safety Data Sheet (SDS), available from the manufacturer or supplier. Never hide a restricted item in a parcel or describe it as something else.
Get ready for a same-day pick-up
Same-day jobs run to tight timings. A little preparation stops the driver waiting and keeps the job on schedule.
- Have the parcel packed, sealed and labelled before the pick-up time.
- Give the size and weight when you book, so the quote matches the job.
- Share access details: entrance, loading dock, gate or building codes, parking and level.
- Name a contact person and phone number at both pick-up and delivery.
- Mention anything heavy, awkward or restricted before the driver arrives.
- Leave it somewhere easy to reach, with any paperwork ready.
Packing orders every day? See when outsourcing warehousing and fulfilment makes sense for your business.
Quick packing checklist
- Box or satchel is sturdy and the right size
- Each item is wrapped, and nothing moves when shaken
- All seams are sealed with H-taping, top and bottom
- One clear label sits on the largest flat side, with no old labels showing
- Both addresses and phone numbers are on the label, with a copy inside
- Dangerous goods are checked and declared to the courier
- Size, weight, access details and contacts are sent with the booking
How PBR Express Logistics can help
Our Same-Day Courier service collects documents, parcels, satchels and small cartons in Newcastle and delivers them the same business day. For larger cartons, pallets or bulky items, our Road Freight service handles one-off jobs and regular runs. Every job is quoted first, and the price is confirmed before pick-up. Request a courier or freight quote with your item sizes and route, and we’ll confirm the details.
FAQs
Can I reuse an old box to send a parcel?
Yes, if it is still rigid with no tears, crushed corners or water damage. Remove or cover every old label and barcode. For heavy or fragile items, a new double-wall carton is the safer choice.
Do I need to write fragile on my parcel?
You can, but don’t rely on it. Parcels may share conveyors and vehicles with other freight, so the packaging must protect the item. Use the box-in-box method and enough cushioning that nothing moves.
Can I send lithium batteries or aerosols by courier?
Sometimes. It depends on the carrier, the transport method and the product. Some carriers restrict or refuse lithium batteries, aerosols and flammable liquids. Tell your courier what you’re sending when you book, and check the product’s Safety Data Sheet.
What should I put on a parcel label?
The recipient’s name, full street address, suburb, state, postcode and phone number. Add your return address and phone number, kept apart from the delivery address. Use one clear label and remove any old ones.
