Introduction:

Air freight is the fastest and most efficient way to transport goods globally. With thousands of flights operating daily, air cargo can move your shipments across continents within hours, making it the ideal solution for time-sensitive items such as perishable foods, medical supplies, electronics, and high-value goods. However, this speed comes with stringent packaging requirements. Given the limited space on aircraft, packages must be compact, structurally sound, and capable of withstanding pressure and temperature fluctuations during flight.

Adhering to air cargo packaging protocols is crucial not only for protecting your shipments but also for complying with the legal standards set by airlines and aviation authorities worldwide. Noncompliant packages may be refused for air transport to maintain safety and security. This guide will walk you through everything you need to know about packaging for air freight shipments.

The Importance of Proper Air Cargo Packaging

While air freight generally offers a smoother transit than ground or ocean shipping, your shipments are still exposed to risks like turbulence, pressure changes, temperature fluctuations, and potential mishandling. Proper, sturdy packaging mitigates these risks and ensures your goods arrive intact. Additionally, compliant packaging meets airline regulations and prevents issues such as crushed boxes or unsecured contents, which could trigger security concerns.

Essential Air Freight Packing Materials

The safety of your air cargo begins with selecting the right packing materials. Here’s what you’ll need:

• Outer Containers: Use double-walled corrugated fibreboards boxes with a minimum edge crush test (ECT) rating of 200 lbs per square inch (PSI) to prevent failure during transit.
• Inner Cushioning: Protect your goods with bubble wrap, air pillows, foam peanuts, or crumpled kraft paper.
• Reinforcements: For heavy shipments, consider using crates, plywood sheets, edge protectors, or double-boxing.
• Securing: Plastic pallet sheets, stretch wrap, and strapping or banding keep palletized or skidded freight securely in place.
• Special Containers: For temperature-sensitive items such as perishable foods or pharmaceuticals, insulated boxes are a must.

Step-by-Step Packing Process

Follow this systematic approach to ensure your air freight shipments are packaged correctly:

1. Outer Box Selection: Choose a double-walled corrugated box rated for at least 200 lbs/sq. inch crush test. Cushion the contents with bubble wrap, foam peanuts, or air pillows.
2. Sealing: Securely close and seal the boxes using reinforced water-activated tape or hot melt adhesive, applying at least three strips per box seam.
3. Labelling: Mark all boxes with shipping names, addresses, UN numbers for hazardous goods, orientation arrows, and handling instructions like “Fragile” or “This Side Up.”
4. Palletized Freight: Place heavier boxes at the base of the pallet, stacking lighter ones on top. Use skids for easier handling.
5. Securing Freight: Use ample stretch wrap, plastic banding, or netting to stabilize the load on the pallet.
6. Final Labelling: Properly label and mark palletized shipments according to airline requirements, including address labels, hazmat markers, gross/net weight, and dimensions.
7. Documentation: Ensure all necessary paperwork, such as air waybills, packing slips, and permits for controlled items, is included.
8. Special Packaging: For temperature-sensitive, perishable, or hazardous materials, use the required internal packaging as per regulations.

Following these steps guarantees that your air freight is immobilized, cushioned, secured, and compliant with all packing protocols, thereby preventing damages and delays.

How Air Freight Size is Calculated

Freight rates and fuel surcharges are determined by the chargeable weight, while storage and other charges are based on the gross weight unless stated otherwise. Here’s how it’s calculated:

• Volumetric Weight: (L x W x H in cm) / 6000
• Chargeable Weight: The greater of the gross weight or volumetric weight becomes the chargeable weight.
• CBM Calculation: Volumetric weight / 166.66

For larger or irregularly shaped freight, the entire secured load is measured as a single unit. Airlines use dimensional weight pricing to maximize cargo hold space, ensuring that bulky but lightweight shipments are charged appropriately. Efficient packaging to reduce wasted space can help lower these charges.

Size and Weight Restrictions

Due to aircraft capacity and operational constraints, air cargo is limited by maximum weight and dimensions. Most airlines impose the following restrictions:

• Length: 150 inches (381 cm) max
• Width: 118 inches (300 cm) max
• Height: 100 inches (254 cm) max
• Total Linear Dimensions: 292 inches (742 cm) max

Weight limits vary by aircraft and route, but shipments over 150 lbs typically require palletization or skidding. While there are no minimum size limits, small shipments may incur surcharges. Pricing is based on the higher of actual weight or dimensional weight, with the latter penalizing oversized, light shipments due to the space they occupy.

Prohibited, Restricted, and Regulated Items

Air transport is subject to stringent regulations regarding the types of goods that can be shipped. Shippers must be aware of these restrictions and ensure that any permitted dangerous goods are packed according to regulatory standards.

• Dangerous Goods: Items like flammable, corrosive, explosive, toxic, or radioactive materials are classified as dangerous goods and require UN-certified packaging, hazard labels, and proper documentation.
• Lithium Batteries: Due to potential risks, lithium batteries are heavily regulated. They must be shipped at less than 50% charge, with adequate circuit protection. Damaged batteries are prohibited.
• Some Perishables: Certain foods, like durians or blue cheese, may be restricted due to odours or natural gas emissions.
• Other Restricted Cargo: Airlines may limit or prohibit items that could leak, contaminate, attract pests, or introduce illegal substances. This includes items like lawn fertilizers, seeds, soil, live animals, and cannabis products.

Always verify commodity-specific restrictions with your air carrier before shipping. Use proper packaging, including UN-rated containers and accurate labelling, to avoid penalties.

Documentation and Labelling

In addition to sturdy packaging, shipments require proper documentation and handling labels, including:

• Air Waybill (AWB): The contract of carriage with details like weights, counts, and descriptions.
• Packing List: Itemised contents of each piece in the shipment.
• Handling Labels: Orientation arrows, hazard warnings, name/address, and more.
• Security Declarations: Certifying screening and packaging integrity.

Final Thoughts

By following airline requirements for packaging, labelling, and documentation, you ensure your air freight shipments are accepted and transported quickly and safely to their final destinations worldwide. With the right preparation, air shipping can seamlessly move your cargo across the globe.