Whilst it was previously uncommon and a somewhat specialist service to send packages and parcels by air, it is far more likely that long-distance and international parcel delivery will incorporate airmail at some point in the journey.

Because of this, if your business often sends goods internationally, they need to be securely packaged and protected for the flight, which can be achieved using custom cardboard boxes designed specifically for the types of products you intend to send.

Choosing the right parcel and indeed the right methodology for packaging is critical to ensure that parcels that travel by air reach their destination without any damage to their contents.

Here are some top tips for packaging parcels intended to travel via airmail.

Choose Sturdy Cardboard Boxes 

Double or even triple-walled boxes are far more suited for travelling long distances, especially when shipping anything fragile enough to be at risk of getting damaged at any point during the loading, unloading and mid-flight steps of the journey.

As well as this, heavy items should be packaged in sturdier, new boxes, as used boxes might be already damaged or could be lacking their strength in other ways.

If necessary, pack your box in another, larger box with filler material around it to maximise the level of protection if the only alternative is overstuffing.

Avoid Hollow Space

Whilst a parcel should not be packed too tightly as it could burst or cause breakages in items that bump against the walls and corners of the packaging or collide with other items in the same box, a box should also not be packed too lightly either.

If there is hollow space left in the box, items can move around, and this can cause potential damage that would only be discovered once it reaches its destination. Using excess paper, bubble wrap or packing peanuts can help with this.

Wrap Items Individually

As well as ensuring you avoid excess space within the parcel, make sure all items are wrapped individually to stop them from getting damaged and knocking against each other.

The best way to stop any issues is to use boxes with dividers, as they can provide additional stability and protection suited for the products being shipped, although this will depend considerably on the products and parcels being sent via airmail.

Fragile items should have at least two inches (5cm) of cushioning material, and be the same distance away from the walls and corners to avoid potential damage.

Items should ideally not touch each other at all, and you should try to pack fragile items away from each other and away from the sides of the box as much as possible.

Choose The Right Filler Materials

Foam peanuts, bubble wrap and cardboard dividers are the best choices for filling out void space and protecting parcels, whilst air pillows and newspaper are not as effective as one might expect when protecting fragile items, although they can be used if you just need filler.

Newspaper shreddings will provide almost no protection from shocks and jolts mid-flight, whilst air pillows are far more prone to bursting than bubble wrap, which immediately puts your fragile items at greater risk of breaking.

All Boxes Need Two Flat Surfaces

Boxes can be made in various sizes, and whilst a uniform shape is ideal, there are cases where it is not entirely practical to ship an item in a cube or cuboid shape without excessive amounts of empty space.

However, regardless of the packaging you use, make sure it has at least two flat surfaces. It needs one to keep it stable when in flight and during mechanical sorting, and another for the label to be affixed to it, read and processed.

This is most important for shipping tube-shaped objects such as maps or posters, which would be best posted in a triangular box rather than a round tube.

Make Sure The Parcel Is Sealed Properly

Many custom storage boxes will have flaps and tabs which allow them to be closed without the need for seals. Regardless, they should be sealed with a sticker or strong tape to ensure they do not open during sorting or flight.

Package Any Display Boxes

Many product boxes are perfectly suited for shipping without adjustment, as they are carefully packaged with stability and preserving the contents in mind. Some even have space for shipping labels.

However, if your product has a display box that you want to avoid being tarnished, damaged or scuffed mid-flight or during automated sorting, make sure to ship it in an outer box.