Amazon packaging requirements for FBA in 2025

A shipment can sit in Amazon’s rejection queue for three weeks because poly bags lacked suffocation warnings. You can lose hundreds on liquid products that leaked and contaminated other inventory during receiving. These aren’t rare horror stories. They happen daily to sellers who treat packaging requirements as suggestions instead of profit-protection rules.

Amazon’s FBA packaging requirements determine whether your inventory reaches customers or gets disposed of at your expense. Understanding these rules not only helps you comply but also protects your investment.

Amazon packaging rules every seller must know

Every FBA unit needs a unique FNSKU that corresponds to exactly one product variation. Different sizes, colors, or conditions require separate FNSKUs. This might seem obvious, but FNSKU mix-ups cause major headaches during Amazon’s receiving process.

Each unit must also have an exterior scannable barcode that’s easily accessible. Don’t place barcodes on corners or curves where scanners can’t read them properly. If your product already has manufacturer barcodes, cover them completely with opaque tape or black marker to prevent scanning confusion during receiving.

Remove or disable theft-prevention devices before shipping to Amazon. Those magnetic strips and security tags that work in retail stores will cause problems in Amazon’s automated fulfillment centers. Inventory that arrives with these devices attached faces immediate processing delays.

Amazon’s prep categories

Amazon’s prep guidance covers 13 different product categories, each with specific requirements. Adult products need opaque black bagging. Apparel requires transparent poly bags with suffocation warnings. Baby products for children under 3 years old need protective packaging for any exposed surfaces larger than one square inch.

Units falling under multiple categories must meet all applicable prep requirements. For example, shampoo and conditioner sold as a set must meet liquid product requirements and include “Sold as set” labeling to prevent separation during fulfillment.

Bagging

Poly bags must be at least 1.5 mil thick and completely transparent so barcodes remain scannable. Bags with openings 5 inches or larger when measured flat require suffocation warnings printed in specific font sizes based on bag dimensions.

The warning text must state exactly: “WARNING: To avoid danger of suffocation, keep this plastic film away from babies and children. Do not use this bag in cribs, beds, carriages, or play pens. This bag is not a toy.” Font sizes range from 10 point for bags under 29 inches total length and width to 24 point for bags 60 inches or larger.

Items requiring bagging include fabric clothing, products with loose parts, small items under 2 inches, powders that spill during vigorous shaking, and hazmat liquids. The bag must fully enclose the item and be sealed with tape or adhesive strips.

Boxing

All boxes must be six-sided and resist collapse under medium pressure. If your box opens easily on its own, secure it with tape, glue, or staples. Perforated packaging must pass a 3-foot drop test consisting of drops on each side and one corner, or it needs poly bag protection with suffocation warnings.

Boxing becomes required when items fail drop tests after other prep methods, when you’re shipping fragile items over 10 pounds (requiring double-wall corrugated), or for specific products like vinyl records that always need boxing protection.

Bubble wrapping

Bubble wrap demands complete product protection with no exposure. Items must pass the 3-foot drop test after wrapping, which involves five consecutive drops: flat on base, top, longest side, shortest side, and on a corner. Use a minimum of two layers with no empty space inside the package.

Barcodes must remain scannable on the outside, requiring ASIN stickers if the original barcode gets covered. Bubble wrap works for fragile items, premium products, and collectibles, but cannot protect sharp items like knives or blades.

Set creation

Set creation applies to any items sold together as a single unit. Bundle everything in bags, boxes, or bubble wrap with clear labeling like “Sold as set,” “Ready to ship,” or “This is a set. Do not separate.” Cover individual unit barcodes so only the set’s barcode faces outward.

Provide unique ASINs for sets when individual units already have separate ASINs. This prevents fulfillment center associates from scanning wrong codes and separating items that should stay together.

Amazon’s product-specific packaging rules

1. Adult content or products

Adult products containing nudity, offensive language, or violent imagery require opaque black poly bags or shrink wrap. The barcode must remain scannable on the outside, and bags need suffocation warnings when applicable. This discrete packaging ensures appropriate handling without exposing inappropriate content.

2. Liquid containers

Non-hazmat liquids over 4.2 oz without secondary seals need cap sealing around twist tops, over flip tops, or vertically over pumps. Apply seals horizontally around screw caps, vertically over flip openings, and ensure pump seals attach to bottles on both sides.

Spray bottles without locking mechanisms require bagging instead of cap seals. Items with double seals, like induction seals, safety rings, or child-resistant caps, often avoid additional sealing requirements.

3. Hazmat and non-hazmat liquids

All hazmat liquids require bagging regardless of size or packaging. Non-hazmat liquids under 4.2 oz typically need no additional prep unless repeatedly damaged during transit. Glass containers need bubble wrap protection, which may also require cap sealing if bubble wrap doesn’t prevent leakage.

Double seals include induction seals, safety rings, metal clips (minimum two required), plastic wrap bands, child-resistant caps, heat shrink wrap, or sealed six-sided boxes. Products with proper double seals often avoid additional prep requirements.

4. Television sets

TVs from 2018 and later from manufacturers like Samsung, Sony, LG, Hisense, Sharp, TCL, and Vizio need ISTA 6-Amazon.com-SIOC certified packaging. This applies to screen sizes 40 inches and larger for 2018 models or 32 inches and larger for 2019 models.

Non-certified inventory faces removal from fulfillment centers and storage fees. Contact approved APASS labs for certification testing if your TV ASIN isn’t on Amazon’s pre-approved list.

5. Plant, animal, food, and OTC products

These products need fully enclosed, sealed packaging with a minimum 90-day shelf life. Food items require expiration dates in 36-point font or larger on both products and master cartons. Lot numbers alone don’t meet requirements.

Products must remain stable between 50-100°F and be permitted for sale in all US jurisdictions. Plant and animal products need double packaging to prevent attracting pests during storage and fulfillment.

6. Granular products

Powders, pellets, and granular materials need spillage prevention packaging. Items that fail vigorous shake tests require poly bagging with suffocation warnings. Consider secondary seals or cap seals for containers with easily openable lids.

Test packaging durability using both 3-foot drop tests and vigorous shake tests to ensure containers won’t spill during normal handling and transportation.

7. Fragile products

Fragile items need protection that passes 3-foot drop tests. This includes glass, ceramics, collectibles, and mirrors. Hardcover books over $60 or softcover books over $75 need bubble wrap protection. Individual units in sets must be wrapped separately to prevent damage.

Use a minimum of two layers of bubble wrap with no product exposure. Styrofoam inserts, foam sheets, or air pillows inside boxes also provide acceptable protection for many fragile items.

8. Hazmat or chemical products

Dangerous goods classified as hazmat require specific preparation based on composition and classification. All hazmat liquids need bagging or heat-shrink wrap regardless of other packaging. Only a limited quantity of hazmat products is acceptable for FBA.

You remain responsible for proper identification and classification according to DOT regulations. Fragile hazmat containers may need both bubble wrap for breakage protection and bagging for spill prevention.

9. Batteries

Battery products need rigid packaging that prevents terminal contact with metals. Acceptable materials include original manufacturer packaging, boxes, clamshells, or blister packs. Avoid zipper bags, shrink wrap, or non-rigid materials.

Button cell batteries require child-resistant packaging with warning statements. Non-rechargeable batteries need sealed, leak-proof packaging, while rechargeable batteries must have safety devices preventing dangerous heat evolution.

10. Packaging sharp units

Sharp items like knives, blades, and scissors must arrive with puncture-resistant packaging that completely covers all sharp edges and points. Hardened blister packs work best, secured so items don’t slide around inside.

Bubble wrap and regular boxes don’t provide adequate protection for sharp items and will cause immediate rejection or disposal. The packaging must remain secure throughout receiving, storage, and delivery to customers.

11. Softlines and baby products

Softlines and baby products need dust and humidity protection through sealed packaging. Items designed for children under 4 years old can’t have exposed surfaces larger than 1 inch by 1 inch.

Footwear must be packaged with no material exposed, either in original boxes or poly bags with suffocation warnings. Remove regular-size hangers but allow mini-hangers for baby clothes.

12. Small products and jewelry

Products with sides under 2⅛ inches need bagging or boxing to prevent loss during fulfillment. Jewelry requires protective packaging regardless of size to guard against dirt, dust, and humidity damage.

High-value jewelry over $2,000 should use extra protective measures, given Amazon’s reimbursement policy limitations. Ensure barcodes remain visible on the packaging exterior for scanning.

13. Packaging plexiglas

Plexiglas products need labels at least 2×3 inches stating the material type. This helps Amazon distinguish them from glass products that require different handling procedures throughout the fulfillment process.

14. Mattress packaging guidelines

Mattresses must be packaged in corrugated boxes and properly categorized under Home & Kitchen > Furniture > Bedroom Furniture > Mattresses & Box Springs > Mattresses during ASIN creation. Proper classification prevents rejection at fulfillment centers.

Smart packaging strategies that save money

How to batch prep efficiently

Group similar products together during prep sessions rather than handling each item individually. This reduces setup time and minimizes mistakes that lead to costly rejections. Create prep stations with all necessary supplies within arm’s reach: poly bags, bubble wrap, tape, labels, and markers organized in containers.

Process products by prep type rather than by SKU. Handle all poly bag items together, then all bubble wrap items, then all set creation tasks. This workflow prevents constant switching between different prep techniques and materials, reducing errors and increasing efficiency.

Measure and pre-cut packaging materials for frequently shipped items. If you regularly send similar-sized products, having pre-measured bubble wrap or pre-sized poly bags speeds up the process significantly while ensuring consistent compliance.

When to use FBA prep services vs. DIY

Amazon’s FBA prep service charges $0.20 to $5.30 per unit, depending on prep type required. Calculate your true hourly rate, including opportunity costs, to make informed decisions about outsourcing versus handling prep internally.

Use FBA prep services when your time costs more than Amazon’s fees. If you’re earning $50 per hour on business development but spending hours on bubble wrap prep, the math favors outsourcing to focus on revenue-generating activities.

Consider hybrid approaches for different product categories. Handle simple bagging internally while outsourcing complex bubble wrap or hazmat prep to Amazon. This balances cost control with time efficiency across your product mix.

Integration with prep workflow tools

Modern prep software streamlines packaging compliance by automating requirement lookups and tracking prep completion. Tools like InventoryLab integrate prep guidance directly into your workflow, reducing errors that cause costly rejections at fulfillment centers.

These systems flag prep requirements based on product categories and attributes during listing creation. Instead of memorizing dozens of packaging rules, you get specific guidance for each ASIN, preventing expensive mistakes before they happen.

Batch processing features group similar prep requirements together, maximizing efficiency during prep sessions. Queue all poly bag items, bubble wrap items, or set creation tasks for dedicated workflow sessions that reduce switching between different prep types.

Compliance checklist and action steps

Create a systematic verification process that catches packaging errors before shipment. This prevents costly rejections and maintains your account health metrics, which can affect your overall seller performance ratings.

• Verify each ASIN’s prep requirements using Amazon’s current guidelines rather than relying on memory for infrequently shipped categories. Cross-reference your prep against the latest requirements since packaging rules can change.
• Test barcode scannability on every unit using a smartphone scanner app. If your phone can’t scan the barcode easily, Amazon’s automated equipment likely can’t either. This simple test prevents reception delays that tie up your inventory and capital.
• Document your prep with photos for items requiring specific techniques. This creates accountability during your prep process and provides evidence if Amazon disputes your packaging compliance later.

Common rejection scenarios to avoid

• Mixed prep requirements within single shipments confuse receiving teams and cause processing delays. Clearly separate and label different prep types to prevent cross-contamination when sending various product categories together.
• Insufficient suffocation warnings on poly bags cause automatic rejections. Double-check warning placement and font sizes against Amazon’s specific requirements. When in doubt, use warnings that exceed minimum standards rather than risk non-compliance.
• Inadequate sharp item packaging leads to immediate disposal without reimbursement. Amazon takes safety seriously and won’t compromise on items that could injure workers. Invest in proper puncture-resistant materials rather than risk total product loss.
• Expired products or insufficient shelf life cause rejections for food, supplement, and cosmetic categories. Always verify expiration dates that exceed 90 days from the shipment date and are clearly visible in required font sizes on both units and cartons.

Don’t let packaging kill your profits

Amazon’s packaging requirements might seem overwhelming at first, but they protect your investment and ensure smooth operations. Each rule exists because someone, somewhere, lost money on a preventable mistake that proper preparation could have avoided.

The sellers who consistently profit on Amazon treat packaging compliance as a competitive advantage rather than a burden. While competitors pay rejection fees and deal with disposal costs, compliant sellers focus their energy on sourcing profitable products and growing their businesses.

Ready to eliminate packaging headaches and focus on growing your business? InventoryLab, part of Seller 365, streamlines your entire prep and shipping workflow with built-in compliance guidance and automated requirements checking. Combined with 9 other essential seller apps in one affordable subscription at just $69/month, you get everything needed to run a profitable Amazon business without juggling multiple software costs.

Try Seller 365 free for up to 14 days and discover how the right tools make compliance effortless while you focus on finding your next profitable products.