5 Must-know tips when preparing for air freight
Air freight is fast, reliable, and ideal for time-sensitive shipments, but it comes with strict regulations, high costs per kilogram, and unique packaging challenges. Whether you’re shipping sensitive electronics, industrial components, or e-commerce orders, packaging and preparation are critical to success.
At Hilltechs, we support manufacturers and exporters with smart, secure, and compliant packaging systems. Here are 5 must-know tips to help you prepare your goods for air freight and avoid costly delays or damage.
1. Use lightweight, durable packaging
Air freight charges are based on dimensional weight, so keeping packaging light without sacrificing protection is key.
Recommended solutions:
- Corrugated boxes with internal bracing
- Anti-static bags for electronics
- Inflatable dunnage airbags to fill voids without adding weight
PRO Tip: Avoid wood or heavy crates unless absolutely necessary. Opt for recyclable, engineered board or foam alternatives when weight matters.
2. Ensure compliance with IATA standards
The International Air Transport Association (IATA) governs air cargo, including rules around labeling, documentation, and packaging integrity. Improper labeling or unsupported packaging can lead to fines or denied shipments.
To stay compliant:
- Use correct handling and hazard labels
- Include clear destination and routing info
- Apply tamper-evident seals or reinforced closures
PRO tip: Keep all export documentation, including invoices, MSDS (for chemicals), and airway bills, accurate and accessible.
3. Secure your cargo with proper void fill and stretch wrapping
Movement during turbulence, loading, or transfers can cause serious internal damage – even inside a closed box. That’s why cargo stabilization is critical.
Solutions from Hilltechs:
- Dunnage airbags: Fill empty spaces in containers or pallets
- Stretch wrap systems: Secure full pallet loads with optimized film usage
- Top sheet dispensers: Protect against dust, moisture, and weather during tarmac transfers
Packaging isn’t just about the box. It’s about load containment and impact resistance.
4. Protect against moisture and pressure changes
Air freight cargo is often exposed to fluctuating temperatures and pressures – especially in non-climate-controlled aircraft holds.
Use protective packaging such as:
- Moisture barrier films or desiccants for electronics
- Foam-in-bag or anti-vibration inserts for fragile items
- Sealed packaging for food, pharma, or chemical products
Electronics, medical devices, and industrial sensors are especially vulnerable to condensation and ESD (electrostatic discharge).
5. Double-check your packing list and destination requirements
Every destination country may have unique rules for labeling, customs documentation, and even packaging materials (e.g., ISPM-15 for wood).
Make sure to:
- Cross-check dimensions, weights, and materials
- Include all commercial and customs documentation
- Confirm that packaging meets both airline and country-specific standards
PRO tip: Delays at customs can cost more than the shipping itself – prevent them with careful prep.
Ready to Elevate Your Air Freight Game?
With the right packaging strategy, air freight becomes faster, safer, and more cost-efficient. At Hilltechs, we provide everything from ESD-safe packaging to automated pallet wrapping and load-securing systems.
Need help choosing the right materials or systems for your next shipment?
📩 Get in touch for a custom packaging consultation.
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