June 10, 2025
Air Freight
Knowing how to prepare your cargo for an air freight shipment is vital; when in transit, your air freight cargo will be handled numerous times and may even have other cargo put on top of it. Therefore it needs to be strong enough to handle the movement that comes with air transportation to avoid potential damages. It is also important to ensure that all standards and guidelines given by the International Air Transport Association (IATA) for safety are met in preparation for transit.
In this article, we’ll explore exactly that; our top tips for packing cargo for air freight as well as our most frequently asked questions on the subject!
Why is packing important for air freight?
Packing is an essential part of ensuring the safe arrival of goods via air freight. Poorly packed goods are responsible for over $6 billion in yearly damages to supply chains, emphasising the importance of proper air freight packaging.
Your freight will undergo handling by ground personnel, and interactions with vehicles such as forklifts and trucks alongside aircraft turbulence when on board. It could even pass through multiple handling points at numerous airports before reaching its final destination. All of these stages must be considered when preparing and packing your cargo, as improper packing can lead to delays, damage, or even rejection of the shipment, ultimately increasing air freight rates and charges due to rebooking or repacking fees.
Air freight size restrictions
Air cargo box sizes for air freight depends on the type of aircraft being used:
- Passenger aircraft: For short-haul flights, the maximum loading height is between 60 and 80 cm. On medium-haul flights, it can be up to 110 cm, and for long-haul flights, it can reach 160 cm.
- Cargo aircraft: These can accommodate much taller cargo, with a maximum height of up to 300 cm (depending on the specific aircraft).
There are also restrictions on the length and width of air cargo. For standard air freight on a passenger aircraft, the maximum dimensions are typically:
- Length: 96 inches (2.44 meters)
- Width: 125 inches (3.15 meters)
- Height: 63 inches (160 cm) for most destinations, but some can handle up to 117 inches (297 cm)
If your cargo exceeds these dimensions, you will need to make special arrangements with the airline, which may involve additional fees. In some cases, you may need to charter a cargo aircraft.
Air freight packing tips
Air freight requires specific packing considerations, all while adhering to rules and regulations around limitations on cargo size, air security requirements and packaging materials. Read on to find out more.
1. Know your cargo dimensions and restrictions
We’ve already gone over the typical air freight maximum heights, however if you are following special equipment packing guidelines you may be allowed to ship cargo that exceeds these dimensions; this will be determined by the maximum height of the aircraft type.
If your cargo is palletised, it will need to fit the below dimensions to go through an X-ray machine:
1.20m x 1.20m x 1.53m LWH, max 1000kg CW per pallet
It is critical that if your cargo is required to go through screening through a metal detector, it is on plastic or cardboard pallets instead of wooden pallets as these are likely to have nails.
2. Understand air security regulations
Air freight security regulations state that your cargo must be examined before export. One of the following methods may be used to conduct the inspection:
- Piece/level examination: The Regulated Air Cargo Agent (RACA) examines each box and item in detail
- Consolidated: Cargo is loaded into unit load devices on pallets and stacked in boxes
- Approved known consignor: Does not need additional inspection or testing before transport
3. Use sturdy boxes for freight packing
To ensure the safety and security of your cargo, use strong and sturdy boxes to store your cargo when transporting by air. Reused boxes, while better for the planet, often don’t provide a high level of protection. We’d advise using double-walled boxes as the layers of corrugated cardboard make it thicker and more durable!
Factors to consider when packing your cargo include:
- Weight: The aircraft may have its own weight restrictions depending on the plane’s maximum take-off weight
- Moisture: Be sure to consider all factors that may cause moisture damage to your cargo, whether that be humidity, leaks or shifts in temperatures
- Pilferage: Consider using a plain box without branding for high-value items to avoid the risks of goods being stolen. It is recommended to get marine insurance for peace of mind.
4. Create space between items
Leave room between products when packing multiple things in a single box to prevent damage in transit. The easiest method is to bubble wrap each item individually and place corrugated inserts between each item for increased protection.
5. Use packing tape
Alongside sturdy boxes, it is recommended to use high-quality, durable packing tape to decrease the chances of your boxes falling apart. Make sure to tightly seal your box, leaving no gaps where water, mildew and other contaminants could enter. Avoid using poor-quality tape as it may lose stickiness during transit, and increase the risk of boxes falling apart.
Where possible, consider using paper tape, as this bonds with the box, creating a stronger seal; signs of tampering are also easier to spot when using paper tape.
6. Label cargo correctly
Your box must be correctly and legibly labelled to comply with air freight labelling regulations and ensure that the transport crew knows who owns the product. Be sure to mark if the box is fragile or top load only.
The same goes for dangerous goods which must be labelled in accordance with international regulations. Dangerous goods that must be declared consist of:
- Mobile phones
- Fireworks, ammunition or explosives
- Cylinders of compressed air, oxygen or liquid petroleum gas
- Aerosol cans
- Camping stoves and equipment
- Fuel or paint thinners
- Matches
- Dry ice
- Detergents, bleach, drain or oven cleaners
- Medicines containing alcohol
- Chemical pesticides/herbicides
- Diving equipment
- Machinery with internal combustion engines
- Any electrical items containing batteries
Incorrectly packaged cargo
If cargo is not packed properly there’s a risk that your cargo will be damaged, unsafe for transportation or could be rejected by the carrier, causing additional costs and delays. To minimise the chances of anything going wrong and affecting your supply chain, engage with a professional freight forwarder who can ensure your cargo is packed properly, safely and in accordance with regulations.
So, how can we help?
Here at AGI Global Logistics we ensure to offer you the very best service, offering a wide range of freight solutions. We specialise in international air freight services, working with a range of carriers who offer real-time air cargo tracking to ensure confidence and control throughout the shipment process.
We also offer a full air freight accreditation service to ensure a prompt and delay-free journey for your air freight. To receive an online air freight quote please get in touch with us today to find out how we can help with your logistics requirements. We look forward to hearing from you, and for all of the latest AGI news, don’t forget to follow us on LinkedIn and Facebook!