Glass, ceramics, candles, cosmetics and electronics break in transit more often than anything else, and every broken parcel means a refund, a return and an unhappy buyer. The good news: most damage can be prevented with the right box, enough cushioning and a few simple steps. This guide shows how to pack fragile items so they survive the courier.
What you need
- A strong box: a 5 ply corrugated box for heavy or very fragile items, or a 3 ply box for light ones. See 3 ply vs 5 ply.
- Cushioning: bubble wrap (60 GSM and above for glass and electronics) or plastic-free honeycomb paper.
- Void fill: crinkle shredded paper, extra bubble wrap or crumpled paper to fill empty space.
- Tape and a warning label: strong BOPP tape, ideally Fragile / Handle With Care printed tape.
How to pack a fragile item, step by step
- Pick the right box size. Leave about 5 cm (2 inches) on every side for cushioning. Too big a box lets the item move; too small leaves no room for padding. The Box Size Finder helps.
- Wrap the item. Wrap it in two or more layers of bubble wrap, bubbles facing in, and tape the wrap closed. Wrap each piece separately if there is more than one.
- Protect weak points. Add extra layers on corners, handles, spouts and screens. Fill hollow items such as cups and vases with paper.
- Cushion the bottom. Put a 5 cm layer of shredded paper or bubble wrap in the base of the box.
- Centre the item and fill the gaps. Place it in the middle and fill every gap on the sides and top so nothing moves.
- Do the shake test. Close the flaps and shake the box gently. If you feel or hear movement, add more filling.
- Seal with the H method. Tape along the centre seam and across both edge seams, top and bottom. Use fragile tape so handlers can see it.
- Label it. Stick the shipping label on the top face, away from seams, and do not cover the barcode with tape.
Which bubble wrap for which item?
| Item | Bubble wrap | Box |
|---|---|---|
| Cosmetics, small bottles, candles | 40 to 50 GSM | 3 ply or mailer box |
| Glassware, ceramics, photo frames | 60 to 80 GSM | 3 ply (light) or 5 ply |
| Electronics, appliances | 80 GSM | 5 ply |
| Mirrors, furniture, heavy glass | 120 GSM | 5 ply, plus stretch film outside |
Bubble wrap starts at 5 metres, so you can try a strength before buying a bigger roll. See the bubble wrap GSM guide for more detail.
Common mistakes
- Reusing an old, soft box: it loses most of its strength.
- Using a courier bag for anything breakable: bags give no protection against crushing.
- Leaving empty space in the box.
- Only one thin layer of bubble wrap on glass.
- Writing “Fragile” with a pen instead of using fragile tape or a clear label.
Frequently asked questions
How much space should I leave around a fragile item?
About 5 cm (2 inches) on every side, filled with cushioning.
Is honeycomb paper as good as bubble wrap?
For light and medium items such as candles, cosmetics and gifts, yes, and it is plastic-free. For heavy glass or electronics, use bubble wrap of 60 GSM or more.
Where can I buy fragile packing material in small quantities?
SecureShip sells bubble wrap from 5 metres, 5 ply boxes from packs of 2 and fragile tape from 2 rolls, with free delivery across India and a GST invoice.
