Packaging Materials

This section outlines the cost of different materials, and whether they can be used when fulfilling orders with Airhouse.

Standard Materials

This include basic cardboard boxes or mailers, tape, fill material, and packing slips. Our in-stock boxes come with different ECT (edge crush testing) ratings. 32 ECT boxes are the most versatile, economical and lightweight option, although we stock 200 ECT boxes, which are stronger, for transporting heavier goods.

Name	Internal Dimensions L x W x H"	Cost
Box (Brown - 32 ECT)	6 x 6 x 5"	At Cost
Box (Brown - 32 ECT)	8 x 6 x 6"	At Cost
Box (Brown - 32 ECT)	10 x 6 x 6"	At Cost
Box (Brown - 200 ECT)	12 x 9 x 7"	At Cost
Box (Brown - 200 ECT)	14 x 7 x 5"	At Cost
Box (Brown - 200 ECT)	14 x 10 x 6"	At Cost
Box (Brown - 200 ECT)	16 x 10 x 10"	At Cost
Box (Brown - 200 ECT)	18 x 12 x 10"	At Cost
Box (Brown - 200 ECT)	20 x 14 x 10"	At Cost
Box (Brown - 200 ECT)	24 x 18 x 12"	At Cost
Polymailer (White - Tear-proof)	9 x 12"	At Cost
Polymailer (White - Tear-proof)	14 x 17"	At Cost
Polymailer (White - Tear-proof)	24 x 24"	At Cost
Bubble Mailer (White)	8.5 x 12"	At Cost
Kraft Paper Fill		At Cost
Bubble Wrap		At Cost
Paper Tape (Brown - Dry Adhesive)		At Cost
Pallet	48" x 40"	At Cost

Dimensional Weight

When any order ships, shipping carriers account for the dimensions of packaging when calculating a shipping price. They look at both 1) the physical weight of the shipment, and 2) the shipment's length, width and height to produce a dimensional weight. You are billed for whichever is greater. Carriers measure dimensional weight using different formulas. Orders sent in larger polymailers in particular may bill at unexpected weights due to products settling in transit.

When fulfilling orders, packers will attempt to use the smallest packaging possible, and will generally use a similar size across your orders, although this is not guaranteed. If you require strict consistency for the size of packaging used across orders, Airhouse recommends providing branded mailers.

Please see our doc on Calculating Shipping Costs for more information on billable weight. If you have questions, please also reach out to your Account Manager.

The below chart shows the dimensional weights of Airhouse-provided packaging. Where blank (i.e. UPS SurePost and USPS), dimensional weight will not apply, and you will be billed at the physical weight. Where you see a weight listed, the shipment will bill at the greater of the listed weight and your shipment's actual weight. For example, a 1 lb shipment in a 12"x9"x7" box will bill at 4-6 lbs.

Box Size	UPS SurePost	USPS	UPS Ground	UPS Air	FedEx Ground	FedEx Air	DHL Express	Length + Girth	Cubic Vol.
📦 6x6x5"	-	-	1 lbs	2 lbs	1 lbs	1 lbs	2 lbs	28 in	180
📦 8x6x6"	-	-	2 lbs	2 lbs	2 lbs	2 lbs	3 lbs	32 in	288
📦 10x6x6"	-	-	2 lbs	3 lbs	2 lbs	2 lbs	3 lbs	34 in	360
📦 12x9x7"	-	-	4 lbs	5 lbs	4 lbs	4 lbs	6 lbs	44 in	756
📦 14x7x5"	-	-	2 lbs	3 lbs	3 lbs	3lbs	4 lbs	38 in	490
📦 14x10x6"	-	-	4 lbs	6 lbs	4 lbs	5 lbs	7 lbs	46 in	840
📦 16x10x10"	-	-	7 lbs	10 lbs	8 lbs	9 lbs	12 lbs	56 in	1600
📦 18x12x10"	16 lbs	14 lbs	9 lbs	14 lbs	10 lbs	12 lbs	16 lbs	62 in	2160
📦 20x14x10"	21 lbs	17 lbs	12 lbs	17 lbs	13 lbs	15 lbs	21 lbs	68 in	2800
📦 24x18x12"	38 lbs	32 lbs	21 lbs	32 lbs	24 lbs	27 lbs	38 lbs	84 in	5184

Non-Standard Materials

Non-standard packaging includes any material that is not listed above. Airhouse does not procure non-standard packaging, but you may be able to use them in our warehouse, with approval and additional charges will apply. Some packaging is not supported due to operational complexity. Please note that all packaging, whether non-standard or standard, is subject to dimensional weight.

Supported Materials

Provided by you:

Branded boxes, mailers or fill
Materials in unique sizes not provided by Airhouse
Materials in unique colors (i.e. white cartons vs. standard brown cartons)
Inner packaging that does not require specific equipment to apply, like apparel sleeves, to be used in projects

Requires Approval

Based on order volume:

Custom wet tape
Custom corrugated inserts
Custom fill (kraft paper, tissue paper, special bubble wrap, etc.)

Not Supported

Labels or materials that require specific equipment to apply, such as tagging guns, unique barcode labels or polystraps

Packaging Processing

This section outlines how packaging is applied to an order. In order to keep fulfillment reliable and on-time, Airhouse strives to standardize all processing for efficiency while allowing as much customization as possible.

Standard Processing

Our recipe for standard processing is designed to be flexible and fit the unique brand and unboxing needs of direct-to-consumer businesses.

Standard processing includes:

One employee can complete the pick and pack process
Two marketing inserts for every order (stickers, printed cards, catalogs, instruction manuals or other paper goods consistent across all of your orders)
Items can be packed into a mailer with no special instructions
Minimal or no materials used during pick and pack

Example #1 - Basic standard pick and pack. The warehouse picks the product using standard Airhouse packaging, fills with kraft paper (non-fragile) or bubble wrap (fragile), seals the packaging, and applies the shipping label
Example #2 - Basic branded pick and pack. The warehouse completes the same tasks, with the same fill, but using a custom mailer that you provide.
Example #3 - Pick and stick (no additional packaging required)

During onboarding, we do our best to help your orders fit our processing guidelines. If we notice an unusual number of orders are being delayed or damaged due to complex or insufficient packaging, your Account Manager will reach out to improve process.

Non-Standard Processing

Complex orders that require extra labor, people or materials to process are considered non-standard. Non-standard orders will not meet our order processing SLAs and can take a day or two longer to ship.

Non-standard processing is billed at the hourly rate and includes:

Orders that require additional labor or people to pick due to weight. This typically applies to heavy or large products like appliances or small furniture over 50 lbs.
Orders that require additional time to complete the pick and pack process due to complexity (i.e. has numerous box pieces to fold and insert, complex kitting at time of pick/pack [i.e. kitting that is not completed during an hourly project], or delicate materials)
Orders that are not for your primary direct-to-consumer channel (i.e. B2B orders). Note that these orders also may not qualify for free standard packaging.

For special projects like shipping B2B, Airhouse can continue to provide standard packaging at cost.
We understand that B2B orders may involve additional complex processes such as the ones listed above. Please confirm details and associated costs with your Account Manager ahead of sending B2B orders or launching any other type of non-standard processing.

Orders that require additional packaging that Airhouse does not provide, or needs modifications to manufacturer-level product packaging

For fragile items like glass, Airhouse can package in bubble wrap, but bubble wrap is sometimes insufficient at protecting products in transit. In such cases, we recommend modifying your packaging on a manufacturer level with custom-fit inner retail boxes or alternate materials.
For heavy items like appliances, Airhouse recommends drop tests conducted with your manufacturer and consulting a packaging consultant. Packages are handled roughly by shipping carriers in transit and often dropped and stacked in trucks and on planes. We cannot modify product-level packaging in the warehouse, i.e. styrofoam, cardboard inserts, repacking complex products inside of product packaging with extra padding or heavy-duty fill, etc. In general, we do not open retail/product-level packaging to modify or assemble your actual products due to liability. Packaging applied in the warehouse can be insufficient at protecting against dents and dings.

Packaging