Packaging for FBA is different from packaging for direct-to-customer shipping. Here's what Amazon requires, what you need to have on hand, and how to set up a prep process that doesn't eat your entire day.

One of the things that slows sellers down when they first start with FBA is the packaging piece. They know they need to send inventory to Amazon's warehouse, but they're not sure exactly how it needs to be packaged, what supplies they need, or how to set up an efficient prep process. This post covers all of it.

From Dana's Story: When we were scaling FBA operations, packaging prep became its own system inside our business. At our peak we were shipping full pallets into Amazon warehouses, and having a dialed-in prep process was the only reason that was manageable. It took time to figure out the right setup — the right poly bag sizes, the right label placement, the right box dimensions to avoid size tier fee bumps. Getting that system right early saves you a lot of rework and money later.

The Core Principle: Your Packaging Needs to Survive the Warehouse

FBA warehouses are large, fast-moving operations. Your items will be stored on shelves, moved by conveyor systems, handled by warehouse staff, and packed alongside other products when orders are fulfilled. The packaging you send needs to protect your items through all of that — not just through a gentle trip from your studio to a customer's door.

Two tests to apply to any FBA packaging:

The drop test. If your packaged item were dropped from about four to six feet, would it survive without damage? If the answer is no, your packaging needs more protection — more bubble wrap, a sturdier box, or a different approach entirely.

The compression test. If a heavier item were placed on top of your packaged product during storage or transit, would your item be crushed or deformed? This is especially relevant for softer goods, items in poly bags, or anything with fragile elements. If your packaging can't withstand compression, you need a rigid outer box or additional structure.

Rigid boxes are the best-case scenario for most items because they provide protection on all sides. When boxes aren't practical due to size or cost, poly bags with appropriate padding are the alternative for many smaller or softer items.

Amazon's Packaging Requirements: What You Must Do

Amazon publishes detailed packaging requirements in Seller Central under their FBA help documentation. Read those before you prep your first shipment — they are updated periodically and the specifics matter. Here are the fundamentals that apply to most handmade sellers:

Every unit needs a scannable outer barcode. For Amazon Handmade FBA sellers, this is the FNSKU label — a unique barcode Amazon generates for each of your FBA listings when you create a shipping plan. This label goes on the outside of each packaged unit so the warehouse can scan and identify it. Print these through Seller Central when you create your inbound shipment and apply them before the items go into your shipping boxes.

Poly bags require a suffocation warning if the bag opening is 5 inches or larger. This warning can be printed directly on the bag or applied as a separate label. If you're using poly bags to package your items, check the opening size and make sure the warning is present if required. Amazon will reject units that arrive without this label where it's required.

Glass and fragile items need specific cushioning. If you sell candles, ceramics, glass items, or anything that can break, Amazon has specific cushioning requirements. Generally this means significant bubble wrap coverage and a rigid outer box. Don't assume your standard product packaging is sufficient — test it against the drop test standard.

No loose items. Every unit that goes to the warehouse must be contained and ready to fulfill. Nothing should be loose inside a shipping box — each sellable unit needs to be fully packaged and labeled before it goes in.

Packaging size affects your fees. Amazon calculates FBA fees based on the size and weight of your packaged unit — not just the product itself. Oversize packaging can push your item into a higher fee tier. When you're designing your FBA packaging, test it against Amazon's size tier definitions to make sure you're not paying more than necessary in fulfillment fees.

Setting Up Your Prep Area

Once you're doing FBA with any regularity, it's worth setting up a dedicated prep area in your workspace. Having the right supplies within reach makes prep sessions significantly faster and less frustrating.

The basics most FBA sellers need:

• A label printer — thermal label printers are far faster and more reliable than printing on regular paper and cutting. Rollo and Dymo are two common options among handmade sellers.
• A scale — you'll need accurate weights for creating shipping plans and for confirming your packaged dimensions.
• Poly bags in multiple sizes — have several size options so you can match bag to product without excessive overage.
• Bubble wrap or air cushioning for fragile items
• Boxes in the sizes you use most for your shipping cartons
• Packing tape and a tape gun
• Suffocation warning labels if your poly bags don't have them pre-printed

Where to Source FBA Packaging Supplies

A few reliable sources for packaging supplies that handmade sellers commonly use:

• Uline (uline.com) — boxes, poly bags, bubble wrap, labels, packing tape. Wide selection, reliable quality, ships quickly. Good starting point for most supply needs.
• Paper Mart (papermart.com) — cotton bags, specialty packaging, boxes. Good for sellers who want more aesthetic packaging options.
• Noble Pack (noblepack.com) — jewelry boxes, tissue paper, gift packaging. Good for jewelry and accessories sellers.
• Bags & Bows (bagsandbowsonline.com) — bags, boxes, ribbon, tissue paper. Good for sellers who want retail-quality presentation packaging.
• Amazon Business — sometimes competitive on pricing for standard supplies, and the convenience of Prime delivery on supplies is useful when you run low unexpectedly.

As your FBA volume grows, it's worth getting quotes directly from manufacturers or wholesale packaging suppliers — per-unit packaging costs become meaningful at scale, and buying in larger quantities can significantly reduce your cost of goods.

Build the System Before You Need It at Speed

The time to figure out your FBA packaging process is before a big selling season, not during it. If you're planning your first FBA shipment, do a test run on a small batch — prep a dozen units, create the shipping plan, apply the labels, box everything up. Work through any issues with your packaging approach, your label placement, and your prep workflow before you're trying to turn around 200 units before a Q4 deadline.

The sellers who struggle with FBA prep are almost always the ones who tried to figure it out under pressure. The ones who have it dialed in built the system when they had time to think.

Ready to Go Deeper on FBA?

Inside The Growth Thread, the FBA content covers packaging requirements, shipment creation, inventory management, and how to build a prep process that scales with your business.

Enrollment isn't always open, but you can get on the waitlist and be first to know when doors open:

Join the Waitlist at TheGrowthThread.com

Not ready for that yet? Read the guide to using Multi-Channel Fulfillment to ship orders from your Etsy shop or website using your FBA inventory — one of the most underused features for handmade sellers doing FBA.