Bad packaging is the number-one cause of damage in international transit. After handling thousands of shipments over two decades, our team has seen it all — crushed electronics, shattered glassware, and leaked liquids that ruined an entire parcel.
The good news: most damage is completely avoidable. Here are the five things we tell every customer before they ship.
Tip 1 — Choose the Right Box
Use a new, double-walled box for anything over 1 kg
Reused boxes look fine but their structural integrity is compromised after the first use. International parcels go through multiple handling points — aircraft cargo holds, sorting belts, forklifts. A double-walled box (often called "heavy-duty") provides significantly more protection than a standard single-wall box.
Box size matters too. Choose a box that fits your item with 5–10 cm of clearance on each side for cushioning material. A box that's too large will allow your item to shift and collide with the walls. A box that's too small may be crushed under stacking pressure.
💡 Quick check: After packing, try the "shake test" — if you can hear or feel movement inside, add more cushioning before sealing.
Tip 2 — Wrap Every Item Individually
Separate items before placing them in the box
Even if you're shipping multiple items of the same type, wrap each one individually in bubble wrap or foam padding. Items that touch each other during transit will collide, chip, or scratch — especially in turbulent air cargo conditions.
For fragile items like glass, ceramics, or electronics with screens:
- Wrap with at least 3 cm of bubble wrap on all sides
- Secure the bubble wrap with tape so it doesn't unravel
- Place the wrapped item in the centre of the box, not touching the walls
- Fill remaining gaps with crumpled paper, foam peanuts, or air pillows
Tip 3 — Seal It Properly
Use proper packing tape — not masking tape or sellotape
Standard household tapes are not designed for the temperature extremes of aircraft cargo holds (which can reach −20°C) or the humidity of tropical warehouses. They peel off, leaving your parcel open to the elements.
Use 50mm wide brown packing tape and apply the H-tape method:
- Tape the centre seam of the top flap, extending 7–10 cm down each side
- Tape both parallel seams on the top
- Repeat on the bottom of the box
Apply at least 3 strips of tape — one along the seam, one on each side. Never use a single strip of tape to close a box.
Tip 4 — Label Clearly and Redundantly
Put the address label on top and include a backup label inside
Shipping labels can get wet, torn, or covered by other stickers during transit. Always place a backup label inside the box with the recipient's full name, address, and phone number. This is the difference between a lost parcel being returned and it disappearing forever.
For the outer label:
- Print clearly — never handwrite on a thermal label
- Cover the label with clear tape to protect from moisture
- Remove or cover any old shipping labels from previous uses
- Ensure the full postcode and country are visible
⚠️ Common mistake: Shipping to Malaysia or Indonesia without including the recipient's phone number. Local couriers often need to call before delivering — without it, your parcel may be held at a depot for weeks.
Tip 5 — Know What Needs Special Packaging
Some items require specific packaging by regulation
DHL Express has strict requirements for certain categories. Using incorrect packaging can result in your shipment being rejected at the depot or delayed at customs.
Liquids: Must be in leak-proof containers, placed in a sealed plastic bag, and surrounded by absorbent material. Each bottle should be sealed with tape around the cap.
Lithium batteries (power banks, laptops, cameras): Must be shipped as separate items from devices that contain them if over 100Wh. Check DHL's guidelines before shipping.
Powder items (protein powder, cosmetics): May be inspected by customs. Use resealable zip-lock bags inside your packaging and declare clearly on the customs form.
Artwork and documents: Use a rigid tube or flat rigid mailer — never fold documents that should remain flat. For framed art, remove the glass before shipping.
When in Doubt, Ask Us
If you're unsure whether your packaging meets DHL's requirements, WhatsApp us a photo before you seal the box. We'll advise you in minutes — it's much easier to fix packaging before pickup than after.
We can also supply packaging materials for an additional fee if you need bubble wrap, boxes, or foam padding.