Packing items for Amazon FBA requires following a specific set of prep, labeling, and boxing rules before your inventory ships to a fulfillment center. Get it wrong, and Amazon will either charge you per-unit fees to fix the problem or reject the shipment entirely. Here’s how to pack everything correctly the first time.
Label Every Unit With the Right Barcode
Each individual unit you send to Amazon needs an FNSKU barcode, which is the unique identifier Amazon uses to track your product inside its warehouses. You can print FNSKU labels from your Seller Central account after listing a product. Print them in black ink on white, non-reflective labels with removable adhesive. The label dimensions must fall between 1 x 2 inches and 2 x 3 inches.
Your label needs to include four things: the FNSKU or ASIN, the product name, and the item condition. Leave at least 0.25 inches of white space on the sides of the barcode and 0.125 inches on the top and bottom so scanners can read it cleanly.
Placement matters just as much as printing. Place the barcode on a flat surface on the outside of the packaging, never on a curve or corner where a scanner might struggle. Keep at least 0.25 inches between the label edge and the edge of the packaging. If your product has any existing retail barcodes (like a manufacturer’s UPC), cover them completely so Amazon’s system doesn’t scan the wrong code. The only barcodes you should leave uncovered are serial number barcodes and Transparency authentication labels.
If you’re shipping case packs where every unit inside is the same product, each individual unit still needs its own FNSKU label. Remove or cover any barcodes on the outer case as well.
When to Use Poly Bags
Poly bagging is required for products that could be damaged by dust, moisture, or contact with other items during storage and shipping. This includes textiles, plush items, products with loose parts, and anything with packaging that isn’t sealed. If the product could arrive at a customer’s door looking used or dirty without a poly bag, it needs one.
Any poly bag with an opening of 5 inches or more must include a printed suffocation warning. The minimum font size for that warning depends on the total of the bag’s length and width added together:
- Under 29 inches total: 10-point font
- 30 to 39 inches total: 14-point font
- 40 to 49 inches total: 18-point font
- 60 inches or more total: 24-point font
The warning text itself should read: “Warning: To avoid danger of suffocation, keep this bag away from babies and children. Do not use this bag in cribs, beds, carriages, or playpens. This bag is not a toy.” Place it in a prominent, readable location on the bag. You can buy pre-printed poly bags with the warning already on them from most packaging suppliers, which saves time if you’re prepping in volume.
Remember to place your FNSKU barcode on the outside of the poly bag, not underneath it. A scanner needs to read it without opening the packaging.
Preparing Fragile and Liquid Products
Glass, ceramics, and anything breakable need enough protective packaging to survive what Amazon calls a drop test. Your packaged unit must withstand being dropped from 3 feet onto a hard surface, five consecutive times, without breaking or leaking. Those five drops test the item flat on its base, flat on its top, flat on its longest side, flat on its shortest side, and on a corner.
In practice, this means wrapping fragile items in bubble wrap or foam padding thick enough that a 3-foot fall onto concrete won’t cause damage. Minor cosmetic damage to the outer packaging is acceptable as long as the product inside stays intact and nothing leaks. If you’re unsure whether your packaging is sufficient, do the drop test yourself before shipping. It takes two minutes and can save you a batch of destroyed inventory.
For liquids, make sure caps and lids are sealed tightly and won’t open during transit. Many sellers add shrink wrap or tape over caps as an extra layer of protection. If a liquid product leaks inside a fulfillment center, Amazon may dispose of the entire unit and charge you for it.
Box Size, Weight, and Packing Rules
Amazon allows shipping boxes up to 36 inches in length for FBA orders. The one exception: if your box contains a single oversized item, it can exceed 36 inches as long as the box isn’t significantly larger than the item itself. Standard individual package weight limits apply, so keep each box at or under 50 pounds. If a box contains only one item that weighs more than 50 pounds, it needs a “Team Lift” label on the outside.
Inside the box, pack units tightly enough that they won’t shift around during transit, but don’t overstuff to the point where the box bulges or can’t close flat. Use void fill like air pillows, packing paper, or foam to eliminate empty space. Avoid packing peanuts, which Amazon discourages because they create a mess at the fulfillment center.
Each shipping box also needs its own FBA shipping label, which you generate in Seller Central when you create your inbound shipment. Place the label on a flat surface of the box where it won’t be taped over or obscured during handling.
What Happens If You Pack Incorrectly
Amazon charges unplanned service fees when inventory arrives at a fulfillment center without proper prep or labeling. These fees typically range from $0.20 to $2.00 per unit, depending on the type of correction needed. Amazon also charges a $0.60 per-unit inbound defect fee for items that don’t meet FNSKU labeling or prep standards.
Those fees add up fast. For sellers moving significant volume, prep-related penalties can consume 1% to 5% of revenue, with spikes during Q4 when fulfillment centers are busiest and least forgiving. In some cases, Amazon may refuse to receive a shipment altogether, leaving you to pay return shipping or abandon the inventory.
A Practical Packing Workflow
Once you understand the individual requirements, the actual packing process follows a consistent sequence for every shipment:
- Inspect each unit for damage, missing parts, or packaging issues before you start prepping.
- Apply product-level prep first. This means poly bagging items that need it, bubble wrapping fragile products, and sealing liquid caps.
- Print and apply FNSKU labels on the outside of all prep materials. Cover any existing retail barcodes.
- Pack units into shipping boxes with appropriate void fill. Keep each box under the weight limit and within dimension limits.
- Create your inbound shipment in Seller Central, print shipping labels, and apply them to each box.
If you’re prepping a large batch, do each step for all units before moving to the next. Labeling 200 units at once is faster and less error-prone than fully prepping one unit at a time. Keep a thermal label printer and a stock of poly bags, bubble wrap, and suffocation warning stickers on hand so you’re not stopping mid-shipment to order supplies.