Key Takeaways
- Amazon increased UK FBA box dimensions to 91.4cm x 63.5cm x 63.5cm with a 22.7kg weight limit from June 2025.
- Packages weighing more than 15kg require “Team Lift” or “Heavy Package” labels on top and sides.
- Six-sided rigid construction with proper sealing is mandatory – certain materials like packing peanuts will cause rejections.
- Suppliers now offer FBA-specific packaging solutions to help UK sellers meet Amazon’s strict compliance standards.
Getting rejected shipments to Amazon fulfilment centres is every seller’s nightmare. Understanding Amazon’s updated packaging requirements isn’t just helpful – it’s absolutely vital for maintaining a profitable FBA business and avoiding costly delays.
Amazon’s Updated UK Box Dimensions & Weight Limits
Amazon significantly expanded their UK FBA box size requirements starting June 20, 2025. The maximum box length for Fulfilment by Amazon (FBA) orders increased from 63.5cm to 91.4cm, giving sellers more flexibility for larger product shipments. Current maximum dimensions stand at length: 91.4cm, width: 63.5cm, height: 63.5cm, with a weight cap of 22.7kg.
These changes represent Amazon’s response to seller feedback about restrictive packaging limitations. However, boxes containing multiple standard-size items must still measure at least 15.2cm (L) x 10.0cm (W) x 2.5cm (H) and no more than 63.5cm on any side for optimal warehouse processing.
For sellers seeking compliant packaging solutions, providers like Globe Packaging manufacture and ship FBA-specific boxes designed to meet Amazon’s exact dimensional requirements, including their popular Standard Parcel FBA boxes at 45x34x26cm.
Critical Weight Categories & Labelling Requirements
1. Standard Weight Boxes (Under 15kg)
Standard weight shipments require no special labelling beyond the mandatory FBA Box ID and carrier labels. These boxes move through Amazon’s automated systems most efficiently and represent the majority of FBA shipments from UK sellers.
2. Heavy Package Requirements (Over 15kg)
Any package weighing more than 15kg must display “Team Lift” or “Heavy Package” labels prominently on both the top and sides. This labelling ensures warehouse staff handle these shipments appropriately and prevents potential injury during manual processing. Missing these labels will result in shipment rejection.
3. Special Weight Considerations
Boxes over 23kg and up to 30kg are allowed only for one oversize item. Items exceeding 30kg require enrollment in the FBA Heavy and Bulky program. These requirements protect Amazon’s workforce and ensure proper handling equipment is available during receipt processing.
Approved vs Prohibited Packaging Materials
Materials Amazon Accepts
Amazon approves several protective materials for shipment interiors. Bubble wrap remains the most popular choice for fragile items, whilst heavy-weight kraft paper provides excellent cushioning for books and documents. Inflatable air pillows offer lightweight protection that doesn’t add significant shipping costs, and polyethylene foam sheeting works brilliantly for electronics and delicate merchandise.
All protective materials must provide at least 2 inches (approximately 5cm) of cushioning between the product and the interior walls of the box to prevent damage during transit and warehouse handling.
Materials That Will Cause Rejections
Amazon strictly prohibits several common packaging materials that create operational difficulties. Packing peanuts top the forbidden list – they create mess, clog machinery, and scatter during box opening. Shredded paper and crinkle wrap cause similar problems in Amazon’s automated systems.
Foam strips, thermocol chips, and styrofoam are equally problematic. These materials don’t provide consistent protection and often break apart, contaminating other shipments. Using prohibited materials guarantees shipment rejection and potential account warnings.
Box Standards & Structural Requirements
1. Six-Sided Rigid Construction
Amazon mandates six-sided rigid boxes that maintain structural integrity throughout the shipping process. Regular Slotted Carton (RSC) designs work best, featuring interlocking flaps that create secure closures. ECT-32 (edge crush test) boxes handle up to 32lbs per inch without collapsing, whilst 200lb burst strength boxes support heavier loads.
Reusing boxes is acceptable provided they maintain structural integrity and all previous barcodes are completely covered or removed.
2. Barcode Management & Scanning Requirements
Every box requires clear, scannable barcodes positioned on flat surfaces away from edges and seams. Labels placed on corners or curved surfaces often become damaged or unreadable, causing processing delays. Amazon’s automated systems depend on perfect barcode scanning for inventory tracking.
When reusing boxes, existing barcodes must be completely obscured with opaque tape or removed entirely. Partially covered barcodes can confuse scanning systems and misdirect shipments.
3. Proper Sealing & Tape Application
Strong packaging tape secures all box flaps and seams. Amazon recommends tape that’s at least 5cm wide for optimal holding strength. The “H-taping” method works best – sealing the centre seam plus both edges creates maximum security during handling.
Avoid using string, elastic bands, or staples as primary sealing methods. These alternatives don’t provide consistent closure and can damage products or injure warehouse staff.
UK Suppliers Meeting Amazon FBA Standards
FBA-Specific Solutions
Several UK suppliers now specialise in Amazon-compliant packaging. These companies understand the precise requirements and manufacture boxes specifically for FBA shipments, eliminating guesswork for sellers.
Beyond basic boxes, UK prep services offer packaging solutions. These services handle product inspection, labelling, and proper packaging, ensuring shipments meet Amazon’s standards before dispatch.
Working with FBA-specialist suppliers reduces rejection risks and saves time spent researching compliance requirements. Many offer next-day delivery, crucial for maintaining inventory levels during peak selling periods.
Choose Compliant Packaging to Avoid Costly Rejections
Non-compliant packaging creates cascading problems for FBA sellers. Rejected shipments delay inventory replenishment, potentially causing stockouts during crucial selling periods. Amazon charges additional fees for non-compliant shipments, and repeated violations can result in shipping privileges being suspended.
Investing in proper packaging from the start costs significantly less than dealing with rejections, re-packaging, and re-shipping. UK sellers who prioritise compliance maintain smoother operations and better relationships with Amazon’s fulfilment network.
The key lies in understanding that Amazon’s requirements exist to protect products, warehouse staff, and operational efficiency. Following these guidelines positions sellers for long-term success in the competitive FBA marketplace.
For packaging solutions that meet Amazon’s strict FBA requirements, choose suppliers who can offer an extensive range of compliant boxes and materials.
