To package fragile items for posting safely, wrap each item in at least 5cm of cushioning, place it in a sturdy double-wall cardboard box that is neither too tight nor too roomy, and seal every edge with strong tape. The golden rule is simple: nothing inside the box should touch another item or the box walls. Get those three things right - a robust box, generous cushioning and a secure seal - and the vast majority of breakages never happen.
Whether you are sending a birthday gift, running an online shop or posting the occasional eBay sale, this guide walks you through choosing the right box, cushioning fragile contents properly, and sealing and labelling your parcel so it survives the journey. It draws on Royal Mail's official fragile-items guidance and our own experience supplying custom printed boxes and packaging to UK businesses.
Start with the right box
The box is your first and most important line of defence. For anything fragile, rigid or sharp-edged, Royal Mail recommends a high-quality, heavy-duty box with a double-corrugated cardboard wall. A double wall box has two layers of fluted board rather than one, giving it far more crush resistance on a busy sorting line. If you want to understand how board strength works, our guide to corrugated flute types explains why the flute profile matters for protection.
Size matters just as much as strength. A box that is too snug leaves no room for cushioning, while a box that is too roomy lets the contents slide around and knock together. Aim for roughly 5cm of clearance on every side of your wrapped item so there is space for a protective layer without the contents rattling about.
It can be tempting to reuse an old shoebox or a battered parcel from a previous delivery, but Royal Mail advises against it. Used boxes are softer, less structurally sound and far more prone to collapsing in transit. If you post fragile goods regularly, it is worth investing in fresh, purpose-made boxes such as our custom printed double wall boxes, which are built for heavier and more delicate contents.
Cushion every item properly
Cushioning is what absorbs the knocks, drops and vibrations a parcel experiences on its journey. Royal Mail's advice is to surround each fragile item with at least 5cm of protective material on all sides. Here is what works well and what to avoid:
- Bubble wrap - the reliable all-rounder. Start with a layer of small-bubble wrap taped snugly around the item, then add a second layer of larger bubbles for extra protection and to fill space.
- Cardboard dividers - essential when you are sending two or more items in one box, as they stop wrapped items knocking against each other.
- Polystyrene loose fill or styrofoam - good for lining the box and filling any gaps once your items are in place.
- Avoid balled-up newspaper - it is flimsy and does little to absorb shocks.
- Avoid air pillows for very fragile items - they can burst, leaving your contents suddenly unprotected.
For awkward shapes such as ceramics or figurines, lay the item down and roll it through several layers of bubble wrap rather than trying to wrap it like a parcel. For bottles and glassware, a moulded insert or dedicated bottle box keeps the neck and base cushioned - our custom printed wine and bottle boxes are designed with exactly this in mind.
Fill the voids and seal it well
Once your items are wrapped and placed in the box, fill any remaining space so nothing can shift. Line the base with loose fill, position your items, then pack around and over them until the box is full but not straining. Try not to overpack, as an overstuffed box can burst open under pressure.
Give the box a gentle shake before sealing. If you hear or feel movement, add more cushioning. When you are happy, seal every edge and opening with strong parcel tape, running it along all seams rather than just across the top. A well-taped box holds its shape far better if it is dropped or stacked under heavier parcels.
Label your parcel clearly
Good labelling protects both your parcel and your peace of mind. Royal Mail suggests the following:
- Place one clear address label on the outside of the parcel.
- Put a second copy of the delivery address, plus your return address and a contact number, inside the box in case the outer label is damaged.
- Add a FRAGILE sticker if appropriate. These are available at most Post Office branches.
- Flatten and tape over any sharp edges, such as staples or metal fastenings.
It is worth being realistic about what a fragile sticker does. It is a helpful visual prompt, but parcels still travel through automated sorting, so it does not replace proper internal protection. Your packaging is what keeps the contents safe. If your item is valuable, consider a tracked or insured service and check the relevant Royal Mail compensation guidance before you post.
Choosing the right box for the job
Matching the box to the contents saves money and reduces waste. For small, light but delicate items such as jewellery or cosmetics, a compact rigid box with an insert is often enough. For heavier or bulkier goods, step up to a double wall box. If you sell online and want a consistent, branded experience, a right-sized custom printed e-commerce box protects the product and reinforces your brand at the doorstep. If you are unsure which postal format your parcel falls into, our guide to Royal Mail parcel sizes helps you choose a box that keeps postage costs down.
A quick note on our printing: we print your artwork in full colour directly onto the top of pre-made stock boxes within a defined print area, so you get a smart branded box without compromising the structural strength that keeps fragile contents safe.
Frequently asked questions
How much cushioning do fragile items need?
Royal Mail recommends surrounding each fragile item with at least 5cm of cushioning material on every side. The item should not be able to touch the walls of the box or any other item inside it. If you can feel movement when you gently shake the sealed box, add more padding.
What is the best box for posting fragile items?
A new, sturdy double-wall corrugated box is best for fragile goods, as the two layers of fluted board resist crushing far better than single-wall or reused boxes. Choose a size that leaves around 5cm of clearance on each side for cushioning, so the contents are protected but not loose.
Can I reuse an old cardboard box for fragile items?
It is better not to. Used boxes are softer and less structurally sound, which makes them more likely to fail in transit. If you do reuse a box, inspect it carefully for dents, tears and weak seams first, and replace it if there is any doubt.
Does a FRAGILE sticker guarantee careful handling?
No. A FRAGILE sticker is a useful prompt, but parcels still pass through automated sorting machinery, so it does not replace proper packaging. Treat it as a bonus on top of a robust box, generous cushioning and a secure seal, rather than a substitute for them.
What should I avoid using as protective packaging?
Royal Mail advises against balled-up newspaper, which is flimsy and absorbs shocks poorly, and warns that air pillows can pop and leave contents exposed. Stick to bubble wrap, cardboard dividers and polystyrene loose fill or styrofoam for dependable protection.
How should I seal a parcel containing fragile items?
Use strong parcel tape along every edge, seam and opening rather than just a single strip across the top. Sealing all the seams helps the box keep its shape if it is dropped or has heavier parcels stacked on top of it.
Ready to protect what you post?
Strong, well-fitted boxes are the foundation of safe posting, and branded ones turn a routine delivery into a memorable arrival. Browse our range of double wall boxes and other custom printed packaging at Fast Printed Boxes, or order a sample to feel the board quality before you commit. Give your fragile items the protection they deserve and your brand the first impression it earns.