Written by: Timur Lesov

August 18, 2025

Updated on August 18, 2025

Shipping personal luggage can be daunting, especially when you wish to avoid purchasing a new box for your suitcase or need to source shipping boxes in bulk. This guide addresses three key topics:

Each section provides detailed, actionable advice based on industry best practices, carrier requirements, cost considerations, and sustainability.

1. Shipping a suitcase without a box
2. Choosing an appropriate shipping box (with dimensional considerations)
3. Where to buy bulk shipping boxes

1. Shipping a Suitcase Without a Box

Many travelers and shippers wonder if they can send a suitcase directly without placing it in an additional shipping container. The short answer is yes, but with caveats.

1.1 Carrier Policies and Guidelines

Major carriers-UPS, FedEx, DHL, and national postal services-each have specific rules for shipping “soft” items like duffel bags, garment bags, or suitcases. Generally:

Before shipping, always verify the carrier’s most recent packaging requirements online or at a local service center.

• FedEx: Allows shipping of duffel or soft-sided items without a box, provided you use FedEx branded packaging (e.g., FedEx Paks) and adhere to weight limits. Hard-sided suitcases, however, must be in a box or crate to protect them and other shipments from damage.
• UPS: Permits shipping non-rigid items in poly bags or specialized envelopes. For a rigid hard-shell suitcase, UPS recommends boxing it to meet their packaging standards and protect the contents.
• USPS: Offers Flat Rate Envelopes and Priority Mail flat-rate boxes, but does not have a standard “bag” option for suitcases. Using a box is generally required.
• DHL: Similar to FedEx and UPS, allows soft items in courier pouches but requires hard items to be boxed.

1.2 Benefits and Drawbacks

Advantages of shipping without a box:

Disadvantages:

• Cost Savings: You save on the cost of a box or crate.
• Reduced Waste: Eliminates extra cardboard, contributing to a greener shipping process.
• Convenience: You avoid the step of sourcing and assembling a box.

• Risk of Damage: Without sturdy external protection, hard-shell suitcases can get scratched, cracked, or dented. Soft suitcases may be punctured or torn.
• Carrier Liability: Some carriers limit liability if you haven’t used approved packaging. You may receive little or no compensation for damage.
• Handling Issues: Loose straps, wheels, or protrusions can catch on conveyor belts and rollers, causing jams or tears.

1.3 How to Prepare a Suitcase for Shipping Without a Box

If you decide to ship the suitcase itself without boxing, follow these steps to minimize risk:

Once prepared, drop off at the carrier location or schedule a pickup. Always ask a service agent to inspect the package; they may recommend additional packaging or mark the parcel “Nonconforming” and limit liability.

1. Clean and Empty: Remove all items. Check pockets and compartments so no loose objects shift and damage the bag.
2. Protect Vulnerable Parts:
   • Wheels: Wrap in bubble wrap or padding to shield from abrasion.
   • Handles and Telescoping Handles: Collapse fully and secure with tape, then pad with bubble wrap.
3. Cushioning Wrap: Use at least two layers of bubble wrap or moving blankets. Secure these with stretch wrap (plastic cling film) or packing tape.
4. Reinforce Corners: Hard corners and edges are most prone to impact damage. Consider foam corner protectors engineered for luggage.
5. Labeling:
   • Place a clear shipping label on a flat, visible surface-ideally on the lid.
   • Affix an “This Side Up” arrow label to guide proper handling.
   • Add a “Fragile” or “Handle With Care” sticker if your suitcase is especially delicate.
6. Seal Zippers and Compartments: Use zip ties or tape to secure zippers. This prevents accidental opening and spillage.
7. Use a Protective Liner: Encase the wrapped suitcase in a large, heavy-duty poly bag. This guards against moisture, dirt, and minor abrasions.

2. Selecting and Sizing a Shipping Box for a Suitcase

If you opt for a more secure method-placing your suitcase inside a shipping box-choosing the right box size ensures cost-efficiency and protection. Below is a methodical approach to sizing and selecting the box.

2.1 Measuring Your Suitcase

Record these as H × W × D (in inches or centimeters).

1. Height (H): Measure from the bottom to the highest point (e.g., wheels-to-top of handle).
2. Width (W): Side-to-side width at the widest point.
3. Depth (D): Front-to-back thickness, including any protrusions like pockets.

2.2 Box Selection Guidelines

A shipping box should exceed the suitcase’s dimensions by at least 2 inches (5 cm) on every side to accommodate cushioning material. Thus, target internal box dimensions:

Your suitcase measures 30″H × 18″W × 10″D. Choose a box with internal dimensions at least 32″H × 20″W × 12″D.

• Internal Height ≥ H + 2
• Internal Width ≥ W + 2
• Internal Depth ≥ D + 2

Example

2.3 Box Styles

• Standard RSC (Regular Slotted Container): Most common. Flaps meet in the middle and tape shut. Good for general use.
• Double Wall RSC: Two layers of corrugated board. Ideal for heavier suitcases or long–distance shipping.
• Die-Cut or Custom Fitted Boxes: Pre-scored and tailored for suitcases. Expensive but minimize movement.
• Bulk Corrugated Sleeves: For drop shipping from warehouses; a sleeve slides over the suitcase on a pallet. Useful for logistics operations.

2.4 Cushioning and Securing Within the Box

After selecting the box:

1. Bottom Layer: Fill box bottom with 2–3 inches of cushioning (packing peanuts, foam sheets, or crumpled kraft paper).
2. Insert Suitcase: Center it so there’s equal space on all sides.
3. Side and Top Cushioning: Fill gaps with packing material to eliminate movement. Ensure all voids are filled.
4. Sealing: Tape along all seams with heavy-duty water-activated tape or 3″ polypropylene filament tape. Avoid thin plastic tape.
5. Edge Protection: Add cardboard edge protectors at corners if the suitcase is heavy or fragile.
6. Label Placement: Place shipping labels on the top flap. Secure additional labels on side panels if needed.

2.5 Dimensional Weight Considerations

Carriers use dimensional weight (DIM) pricing for large, lightweight packages. DIM weight in pounds (lb) is calculated as:

$$ \text{DIM weight} = \frac{\text{Length} \times \text{Width} \times \text{Height}}{\text{DIM divisor}} $$

To minimize DIM charges:

• Standard DIM Divisor: 139 (inches) in U.S. domestic shipments.

• Pick a box that closely hugs your suitcase’s contours without excess volume.
• Use minimal but sufficient cushioning.
• Consider splitting multiple items into separate shipments if one box is too large.

3. Where to Buy Bulk Shipping Boxes

For businesses, frequent movers, and thrift shop owners, sourcing shipping boxes in bulk can drastically reduce per-unit costs. This section outlines reliable suppliers, key considerations, and budget-saving tips.

3.1 Types of Bulk Suppliers

1. Corrugated Box Manufacturers
   • Local or regional corrugators often offer custom sizes and volume discounts.
   • Lead times can be longer (2–4 weeks) for custom runs.
2. Packing and Shipping Retailers
   • Uline (uline.com): Extensive catalog, next-day shipping options, and volume discounts.
   • The Packaging Wholesaler: Focuses on eco-friendly and bulk options.
3. Online Marketplaces
   • Amazon Business: Bulk case pack options with prime shipping benefits.
   • eBay Sellers: Often move overstock or discontinued sizes at steep discounts.
4. Recycled and Sustainable Box Suppliers
   • Paper Mart: Offers recycled boxes; good for green initiatives.
   • EcoEnclose: Specializes in post-consumer recycled and compostable packaging.
5. Office Supply Chains
   • Staples, Office Depot: Offer quantity discounts and occasional B2B pricing tiers.

3.2 Factors to Consider When Buying in Bulk

3.2.1 Box Strength and Grade

• ECT (Edge Crush Test) Rating: Indicates stacking strength.
• 32 ECT: Suitable for boxes up to ~30 lbs.
• 44 ECT: Supports heavier loads up to ~65 lbs.
• Bursting Strength: Measures resistance to puncture. Higher is better for heavy suitcases.

3.2.2 Wall Construction

• Single Wall: Economical, for up to ~40 lbs.
• Double Wall: For heavier or more fragile contents.
• Triple Wall: Industrial use, pallet shipping.

3.2.3 Dimensional Options

• Standard Sizes: Easier to find and often cheaper.
• Custom Sizes: Reduce waste and DIM charges but come with minimum order quantities (MOQ).

3.2.4 Sustainability Credentials

• Post-Consumer Recycled Content: Look for 30–100% recycled fiber.
• Certifications: FSC (Forest Stewardship Council) or SFI (Sustainable Forestry Initiative).

3.2.5 Cost Considerations

• Unit Price: Decreases at larger quantity tiers (e.g., 100, 250, 500, 1000 units).
• Shipping Fees: Often substantial for large-weight orders. Negotiate freight terms (FOB origin vs. FOB destination).
• Storage: Ensure you have adequate warehouse space to avoid overflow fees.

3.3 Recommended Suppliers and Pricing Ranges

Note: Prices indicative as of mid-2025 and subject to change. Always request updated quotes.

Conclusion

Shipping a suitcase-whether boxed or unboxed-requires careful attention to packaging guidelines, dimensional weight, and carrier policies. When opting out of an outer box, take extra steps to wrap, cushion, and label the suitcase properly to reduce damage risk and protect carrier liability. If you choose to box your suitcase, select a container that is just slightly larger than your luggage’s dimensions to optimize protection and minimize DIM weight charges.

For businesses and frequent shippers, buying bulk shipping boxes offers cost savings and operational efficiency. Evaluate suppliers on factors including box strength, price tiers, sustainability credentials, and lead times. With the right preparation and materials, shipping luggage can become a streamlined, reliable part of your logistics process.

Timur Lesov

Eco-freak, nerd, and green technology fanatic. I’m in favor of making eco-friendly living simple as well. I graduated from Berkeley in 2017. Studied environmental science and all things sustainability related. I create content and share simple tips for greening your everyday life. I think even small changes can make a huge difference and we can build a cleaner and more sustainable future.