Must-Knows for Shipping Large-Sized Branded Goods: FBA Warehousing Size Limits and Pallet Requirements

In the cross-border e-commerce sector, large-sized branded goods (such as bulky furniture, large home appliances, and fitness equipment) have become core product categories for many sellers due to their high unit prices and strong brand premium. However, when shipping these goods into Amazon’s Fulfillment by Amazon (FBA) warehouses, the rejection rate due to oversized dimensions or non-compliant packaging is as high as 15%, directly causing chain losses such as warehouse detention and sales disruptions. Combining Amazon’s latest policies and practical cases, this article systematically breaks down the size and weight limits, pallet technical standards, and full-process compliance key points for large-sized goods entering FBA warehouses, providing brand sellers with actionable shipping guidelines.

I. Core Definition Standards for FBA Large-Sized Goods

Accurately identifying the type of large-sized goods is the prerequisite for compliant shipping. Amazon does not define “large-sized goods” solely based on a single indicator of weight or size; instead, it adopts a multi-dimensional classification system combining product characteristics and shipping methods, with slight variations in standards across different marketplaces.

(1) Definition Based on Weight

Across global marketplaces, products with a single-piece weight exceeding 23kg are generally classified as heavy large-sized goods. This threshold is set based on the safety standards for manual handling in Amazon warehouses. Further subdivisions are as follows:

• Light large-sized goods: Products weighing 23kg to 45kg must be labeled with “Team Lift” to indicate that two warehouse staff are required for collaborative handling;
• Heavy large-sized goods: Products weighing over 45kg must be labeled with “Mech Lift” and require equipment such as forklifts for loading and unloading;
• Ultra-heavy limits: The U.S. marketplace can accept single-piece goods with a maximum weight of 590kg (approximately the weight of 5 refrigerators), while the European marketplace has a single-piece weight limit of 120kg due to warehouse equipment constraints.

It is particularly important to note that Amazon adopts the pricing rule of “taking the larger value between actual weight and dimensional weight”. For the U.S. marketplace, the dimensional weight is calculated using the formula “(Length × Width × Height) ÷ 139” (all units in inches). If the calculated result exceeds the actual weight, the dimensional weight will be used to calculate fees and apply limit standards.

(2) Definition Based on Dimensions

Dimensional limits must meet three requirements simultaneously: maximum single-side length, girth, and stacking height:

1. Maximum single-side length limit: The longest side of standard large-sized goods must not exceed 158cm. If it exceeds 270cm, the product is classified as “oversized goods”, and a special warehouse entry permit must be applied for in advance from Amazon;
2. Girth calculation rule: Girth = (Second longest side + Shortest side) × 2. The total perimeter obtained by adding the girth to the longest side must not exceed 330cm. This standard is designed to match the dimensions of warehouse shelves and shipping containers;
3. Stacking adaptability requirement: A single product must be able to withstand the stacking weight of at least 3 layers of the same type of products. The outer carton must pass the ISTA 3A stacking test; otherwise, an additional “Non-Stackable” label must be affixed.

(3) Category-Specific Definitions

Some special product categories must be handled according to large-sized goods standards even if they do not meet the weight or size thresholds:

• Furniture category: Assembled furniture sets, even if a single piece weighs less than 23kg, must be shipped on pallets if the overall packaged size exceeds 63.5cm;
• Home appliance category: Appliances with compressors, such as refrigerators and washing machines, must comply with large-sized goods packaging and warehouse entry standards regardless of their weight;
• Irregularly shaped products: Products with protruding or deformable shapes (such as metal brackets for fitness equipment) have their limits calculated based on the dimensions of the largest external cuboid.

II. Detailed Size and Weight Limits for FBA Warehouse Entry Across Major Global Marketplaces

Due to differences in warehouse facilities, labor costs, and transportation networks, Amazon’s marketplaces have developed differentiated warehouse entry limit standards. Brand sellers must accurately adapt to their target markets to avoid compliance risks caused by a “one-size-fits-all” approach.

(1) U.S. Marketplace: The Most Flexible Market Standards

As Amazon’s largest overseas marketplace, the U.S. marketplace has the most flexible limits for large-sized goods and supports multiple shipping methods:

• Basic limits: The longest side of a single product ≤ 158cm, total perimeter (girth + longest side) ≤ 330cm, single-piece weight ≤ 590kg;
• Pallet loading limits: Total height of a single pallet (including the pallet itself) ≤ 1.82m, total weight ≤ 1500lbs (approximately 680kg);
• Special exemptions: Products participating in the “Amazon Heavy & Bulky Logistics Program” can have their longest side relaxed to 274cm, but an application must be submitted in the seller’s backend 7 days in advance.

The U.S. marketplace has strong compatibility with packaging materials, allowing the use of pallets made of wood, plastic, and other materials. However, food products must use wooden pallets of Grade B or higher certified by the FDA.

(2) European Marketplace: Regional Differences Under Unified Standards

The European marketplace has unified most standards through the Pan-European Program (Pan-EU), with 31.5kg serving as a key threshold:

• 23kg – 31.5kg: Can normally use the European Fulfillment Network (EFN) to support cross-country shipping;
• Over 31.5kg: Must be sent to dedicated large-sized goods warehouses, cannot participate in EFN and Pan-EU services, and requires separate inventory preparation by country;
• Strict dimensional limits: All marketplaces uniformly require the longest side ≤ 175cm, total perimeter (girth + longest side) ≤ 300cm, and pallet height ≤ 1.27m.

The European marketplace has strict environmental requirements for pallets. Wooden pallets must bear the IPPC heat treatment mark (the stamp must include the HT code, country code, and enterprise registration number); otherwise, they will be detained by customs.

(3) Japanese Marketplace: Refined Dimensional Classification

Due to its small land area and limited warehouse space, the Japanese marketplace has more stringent limit standards and adopts a four-level classification system:

1. Small large-sized goods: Weight 23kg ≤ W ≤ 30kg, longest side ≤ 120cm, girth ≤ 240cm;
2. Medium large-sized goods: Weight 30kg < W ≤ 50kg, longest side ≤ 150cm, girth ≤ 270cm;
3. Large large-sized goods: Weight 50kg < W ≤ 100kg, requires separate warehouse entry appointment, longest side ≤ 180cm;
4. Oversized goods: Weight > 100kg or longest side > 180cm, must be shipped by Amazon’s cooperative logistics providers.

The Japanese marketplace specifically requires that the outer cartons of all large-sized goods must be labeled with the Japanese phrase “重い物注意” (Caution: Heavy Item). Additionally, pallets must be of the standard size 110cm × 110cm, with a tolerance of no more than ±1cm.

III. Core Technical Requirements and Operational Specifications for FBA Warehouse Entry Pallets

As the “mobile shelves” for shipping large-sized goods, the compliance of pallets directly determines the success rate of warehouse entry. Amazon has clear technical standards for pallet materials, dimensions, stacking methods, etc., with 80% of warehouse entry issues concentrated in the pallet link.

(1) Pallet Material and Qualification Requirements

Pallets made of different materials have significant differences in applicable scenarios and compliance key points. Brand sellers must select pallets based on product characteristics:

1. Wooden pallets: The most cost-effective conventional choice, which must meet three core requirements:

• Material standards: Must use GMA Grade 1A pine or hardwood pallets, with a board thickness of ≥ 1.8cm and a load-bearing capacity of ≥ 1000kg;
• Pretreatment requirements: Remove all exposed nails and splinters, install plastic corner protectors at the four corners, and subject the surface to heat treatment (HT) or fumigation;
• Certification marks: For international trade, must bear the IPPC mark; food products require additional FDA certification documents.

2. Plastic pallets: Suitable for high-value and moisture-sensitive products, must comply with ISO 1161 standards, weigh ≥ 15kg, and have a service life of ≥ 3 years;
3. Composite pallets: Made of wood fiber and plastic composite materials, must pass SGS strength testing, and are only accepted by the U.S. and UK marketplaces.

Sellers should be wary of the “used pallet trap” – second-hand pallets may have hidden damages that cause goods to tilt during transportation. It is recommended to choose brand-new pallets with brand logos.

(2) Pallet Size and Basic Parameter Specifications

Amazon globally recognizes only two standard pallet sizes; a deviation exceeding ±2cm will result in direct rejection:

• International standard: 120cm × 100cm (suitable for most marketplaces in Europe and Asia);
• U.S. standard size: 48 inches × 40 inches (approximately 122cm × 102cm, exclusive to the U.S. marketplace).

The physical parameters of the pallets themselves must meet the following requirements:

• Height: 14cm – 16cm (including the thickness of the bottom and top boards);
• Fork entry: A fork entry space of ≥ 10cm must be reserved on all four sides to ensure that forklifts can operate from any direction;
• Load-bearing capacity: Static load ≥ 4000kg, dynamic load ≥ 1000kg, rack load ≥ 1500kg.

(3) Goods Stacking and Securing Technical Standards

Stacking methods directly affect the stability of goods. Amazon mandates the adoption of “risk-controllable” stacking solutions:

1. Stacking principles:

• Uniform distribution on the same layer: Place heavier goods on the inner side of the pallet and lighter goods on the outer side, with a weight deviation of no more than 5kg;
• Staggered arrangement between upper and lower layers: Adopt the “bricklaying” stacking method (similar to wall construction), where gaps between goods in upper and lower layers are staggered to avoid concentrated vertical stress;
• Single SKU per pallet: Unless labeled with “Mixed SKU”, only one SKU of goods can be placed on a single pallet.

2. Height limits:

• Standard stacking: Total height (including the pallet) ≤ 1.27m, suitable for most marketplaces;
• Double-layer stacking: Only allowed in the U.S. marketplace, total height ≤ 2.54m, and detachable columns must be installed between the two layers for reinforcement;
• Reserved space: A gap of ≥ 5cm must be reserved between the top of the pallet and the goods to facilitate warehouse label scanning.

3. Securing measures:

• Stretch film requirements: Use transparent stretch film with an elongation rate of ≥ 300%, wrap spirally from the bottom, with an overlap rate of ≥ 50% per loop, and fully cover the top;
• Reinforcement aids: Install paper corner protectors at the four corners, with a height equal to the goods, and secure them with packing straps in a crisscross pattern, with a packing strap tension of ≥ 150 Newtons;
• Waterproof treatment: For outdoor transportation, cover the top with a waterproof cloth, fix it to the four corners of the pallet with nylon ropes, and let the waterproof cloth hang down to 2/3 of the goods height.

(4) Pallet Labeling and Marking Specifications

Labels are the “ID cards” for goods entering the warehouse; missing or incorrect labels will result in failure to store the goods.

1. Label types and positions:

• FBA pallet labels: Must be affixed one on each of the four sides of the pallet, 10cm from the top, with a size of ≥ 4 × 6 inches, printed using waterproof carbon tape;
• Carrier labels: Affixed to the upper right corner of the front side of the pallet, with a distance of ≥ 5cm from the FBA label;
• Special marks: Affix “Mech Lift”/”Team Lift” labels for overweight goods, red “Fragile” marks for fragile goods, and “Mixed SKU” labels for mixed-load goods.

2. Label quality requirements:

• Material: Use matte polyester label paper, with a temperature resistance range of -20℃ to 60℃;
• Clarity: Barcode scanning pass rate ≥ 99%, and text must be clearly legible;
• Protection: Cover the label surface with a transparent protective film to prevent wear during transportation.

IV. Full-Process Compliance Operation Guide for Large-Sized Goods Entering FBA Warehouses

Compliant shipping not only requires meeting static standards but also runs through the entire process from goods preparation to warehouse entry. Brand sellers must establish a three-level management system of “pre-planning – in-process control – post-verification” to minimize compliance risks.

(1) Goods Preparation Stage: Standard Pre-Setting and Scheme Design

The compliance of the goods preparation link directly determines the smoothness of subsequent processes. It is recommended to start preparation work 1-2 months in advance:

1. Accurate calculation of product parameters:

• Use an electronic scale with an accuracy of 0.1kg for weighing, and a laser range finder to measure dimensions (taking data from the most protruding points);
• Calculate the dimensional weight using the formula for the target marketplace, compare it with the actual weight to determine the pricing standard;
• Create a “product parameter card” marking core information such as SKU, weight, dimensions, and stacking grade.

2. Customized packaging solutions:

• Basic packaging: Use 5-layer corrugated cartons with “Heavy-Duty Packaging” marked on the carton, and a compressive strength of ≥ 1500kPa;
• Internal protection: Install 5cm-thick foam corner protectors on the corners of furniture products, use independent grid layered packaging for glass products, and adopt double-layer sealing + upright placement for liquid products;
• Filling materials: Prohibit loose materials such as shredded paper and foam particles; prioritize the use of degradable bubble film with a thickness of ≥ 0.5mm.

3. Selection of shipping methods:

• Large sellers: Choose the “Dragon Boat Program” for direct shipping from China, apply for warehouse locking services to avoid split warehousing, and reduce shipping costs;
• Medium and small sellers: Adopt the overseas warehouse transfer model, first transport goods to the overseas warehouse in the target country, complete labeling and palletizing, and then ship to the FBA warehouse for higher flexibility;
• Emergency orders: For goods weighing 23kg – 30kg, the combination of air freight + truck delivery can be selected; for goods over 30kg, sea freight + full container shipping is recommended.

(2) Palletizing Stage: Standardized Operation and Quality Verification

Palletizing is a core compliance link; it is recommended to establish an “SOP Operation Manual” to ensure standardization:

1. Pallet pre-treatment:

• Check pallet integrity: No cracks, no exposed nails, and a gap between the bottom and top boards of ≤ 3cm;
• Cleaning and disinfection: Wipe the surface with a neutral detergent; for pallets used for food products, ultraviolet disinfection is required;
• Mark verification: Confirm that IPPC, FDA, and other certification marks are clear and complete.

2. Stacking operation steps:

Step 1: Lay an anti-slip mat on the pallet surface, aligning the edges with the pallet;

Step 2: Stack according to the principle of “heavier goods at the bottom, lighter at the top; larger goods at the bottom, smaller at the top”, with a height difference of ≤ 3cm between each layer;

Step 3: Secure each 3 layers with packing straps horizontally, and install a bearing plate on the top layer;

Step 4: Wrap the stretch film spirally upward from the bottom, cover the top, and then wrap downward to the bottom to finish.

3. Quality self-inspection checklist:

• Appearance: No goods tilting, no packaging damage, and no loose stretch film;
• Dimensions: Use a tape measure to measure the total height, length, and width to confirm compliance with marketplace limits;
• Stability: Push the side of the pallet with force; a displacement of no more than 2cm is considered qualified;
• Labels: Test all labels with a barcode scanner to ensure successful scanning.

(3) Shipping and Warehouse Entry Stage: Appointment and Abnormal Handling

1. Warehouse entry appointment:

• Submit an appointment application in the seller’s backend 72 hours in advance, filling in information such as the number of pallets, weight, and vehicle type;
• The U.S. marketplace requires the provision of a BOL (Bill of Lading), including core information such as the carrier name, PRO number, and PO number;
• The European marketplace requires the simultaneous provision of ESG compliance documents (such as packaging recycling certification).

2. In-transit monitoring:

• Require the carrier to provide GPS positioning services to track the location of goods in real-time;
• Set up abnormal alerts: If transportation is delayed by more than 24 hours, the emergency response plan must be activated immediately;