How to Package Products for Shipment in Extreme Weather Conditions

Packaging and shipping items always require thoughtful planning, but extreme weather conditions can introduce additional risks that are important to consider. Whether your shipment encounters intense heat, freezing temperatures, heavy rain, humidity, or snow, using packaging that can withstand these elements is key to protecting the contents inside.

In this post, we outline several tips to keep in mind when you are packaging products for your personal or professional shipments.

Consider the risks that come with shipping in certain weather conditions

Before deciding how to package a product for extreme weather conditions, it is first important to consider what your shipment will be up against. Warm temperatures can weaken tape and adhesives, and cause certain items such as cosmetics to melt, while cold, wintry weather can lead to ice buildup, reduce tape strength, and potentially create moisture issues. Rain and humidity can also deteriorate shipping containers, like cardboard boxes, and smudge shipping labels.

Determining your packaging strategy based on what you’re shipping and the seasonal weather conditions your shipment may face is essential.

Choose the right shipping container and outer packaging

This is what will be up against the weather conditions, so as your first line of defence, choose study materials that will remain strong.

• Pick a heavy-duty corrugated box: Double-wall corrugated boxes can provide extra strength and resistance to heat/humidity that can weaken thinner cardboard. Corrugated boxes can also help protect items in cold temperatures, where moisture from rain or snow can weaken cardboard or crack plastic.
• Select the right size: Empty air inside a shipping container can increase exposure to cold and moisture, so it is always best to choose one that is not too big compared to the items inside, but that still leaves room for any necessary cushioning material(s).
• Consider poly mailers: If you are shipping small, non-fragile items, consider a poly mailer, which is durable and water-resistant.

READ MORE: What Type of Cardboard Box Should You Use When Shipping?

Create a waterproof exterior and an insulated interior

From moisture to temperature fluctuations, exposure to certain conditions can weaken packaging materials and damage the products inside. Consider the following protective measures to help strengthen the exterior of your shipment:

• Choose corrugated boxes with moisture-resistant coatings or liners. These boxes are designed to maintain their structure even in moist conditions.
• Wrap the outer box with stretch wrap to create a barrier against rain and slush during loading and delivery. Please note that while doing so will provide additional protection, you will likely incur additional handling fees by your preferred courier at pick up.
• For temperature-sensitive items, use insulated box liners made from foam or reflective thermal material, which can help slow the transfer of heat in summer and cold in winter.

Fill the empty spaces inside the box with the right packaging materials

Cushioning materials can help fill gaps in a shipping container while reducing movement and protecting the container from the item’s sharp edges. In extreme weather conditions, the right materials also help maintain structural integrity and reduce exposure to high temperatures. Packing peanuts and air pillows can be great options. However, if you’re shipping in cold climates corrugated inserts can perform better than air pillows, which may lose their firmness at low temperatures.

LEARN MORE: How To Choose the Right Packaging Fillers

Add an interior lining

Protecting a package against certain weather conditions can sometimes start from the inside out, depending on what you’re shipping. For example, if you’re shipping items that can melt, thaw, or contain liquids, line the inside of the shipping container with a thick foam board* on all sides, and place the items in a secure plastic bag. That way, the outside of your shipping container won’t weaken and become even more exposed to weather conditions if the products inside were ever to melt or create moisture.

*Foam board is also known as bead board, liner board or insulated foam liner.

Seal all box seams with tape

If you’re dealing with wet conditions, applying tape to all seams of a box can help prevent water from seeping in. If you’re particularly worried about extreme cold temperatures, heavy-duty, water and weather proof tape is a great choice.

Protect shipping labels

The shipping labels is one of the most critical parts of a package. If it becomes smudged or torn due to extreme weather, it could delay or misroute shipments. To prevent this, always use high-quality adhesive labels meant for shipment, as standard adhesive could soften or lift from a box in hot temperatures or fail to adhere in cold temperatures. Additionally, be sure to place the shipping label on a clean, dry surface, not on a taped seam, to improve adhesion.

For even greater protection, place the shipping label in a clear adhesive shipping pouch or cover it with clear, heavy duty water and weather proof tape to help keep important details visible.

Add gel packs to maintain temperature

For temperature-sensitive items, gel packs can help maintain a safer internal temperature during transit, which is especially important during warmer months. Gel packs work by absorbing heat, which slows the rate at which the temperature rises inside the package.

Be sure to freeze gel packs completely before packing. Partially frozen packs will not provide sufficient cooling. Use multiple gel packs when shipping for longer transit times or when sending larger packages. Place the gel packs around the items to help maintain a more consistent internal temperature.

To manage condensation as the gel packs thaw, place them in sealed plastic sleeves or wrap them in waterproof material to prevent moisture from damaging the product packaging. You could also add insulation, such as an insulated foam liner board, on all sides, to slow heat transfer and prevent the gel packs from warming too quickly.

Shipping with The UPS Store

Plan your next shipment with The UPS Store! Our packing experts can help your shipment face whatever weather comes its way. We also offer fast delivery options to minimize the time packages are exposed to extreme conditions. Learn more on our Packaging & Shipping Services page.

We also offer a Pack & Ship Guarantee, available only at The UPS Store. If a participating The UPS Store® location packs your item using only new materials purchased at that participating location, and ships the package via UPS (on that participating location’s applicable UPS account) and that item is damaged or lost in transit, you’ll be reimbursed. Find out all the details here.

Reach out to The UPS Store at a location near you to get started.