All Things Shipping
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Oct 19, 2021

How E-commerce Merchants Are Cutting Costs Shipping Heavy Items

One unique and often expensive challenge e-commerce merchants face comes in the form of shipping heavy items. Figuring out the right packaging, limiting dimensional weight, and deciding on shipping insurance are just a few of the factors that come with shipping bigger and heftier products.

However, there are steps e-commerce businesses are taking to limit the cost of shipping heavy items.

While it may seem like the weight of your business is on your shoulders, the weight of your packages don’t have to crush your bottom line. 

How Major Carriers Measure Heavy Items

When shipping heavy packages for your e-commerce business, it is important to note how major carriers measure heavy items. Each of the four major national carriers in the U.S. have their own rules when it comes to the weight and size of their shipments. 

To avoid any oversize charges you’ll want to take these into consideration.

USPS Package Weight Limits

USPS has the lowest weight limit for an individual package of all the major carriers. Most services abide by the 70 lb limit and anything beyond that will face some substantial upcharges. 

You’ll also be charged more if the package you’re shipping is longer than 108 inches or when the combined girth and length is less than 130 inches.

UPS Package Weight Limits

The weight and size limits are greater when shipping heavy packages with UPS. An individual package can weigh up to 150 pounds. The size of the package can be up to 108 inches long and 165 inches in girth and length combined.

If your package weighs any more than this, you can still ship with UPS though there will be an Over Maximum Limits charge.

FedEx Package Weight Limits

With FedEx services such as FedEx Ground, FedEx Home Delivery, and FedEx Express international services, the maximum weight will be 150 lbs with a maximum length of 108 inches and 165 inches when you combine length plus girth. 

If you plan on shipping with FedEx Express in the US, the only difference is that the maximum length can be 119 inches. Same as UPS, you can ship heavier packages but be aware of an  additional charge in shipping price.

DHL Package Weight Limits

Of all the major national carriers, DHL has the largest weight limit for shipping heavy items. The weight limit set is 70kg which translates to 154.3 lbs. The  limits when it comes to the dimensions of the package is smaller which is set at 120 cm (47.2 lbs.)

Anything larger or heavier than these limits can possibly face an additional fee of $89 per package.

Top Tips For E-commerce Businesses Shipping Heavy Packages

There are some things to keep in mind or actions to take when looking to cut costs shipping heavy packages for your e-commerce business. 

1.) Package Tightly To Avoid Dimensional Weight Charges

2.) Keep Inventory Near Customers

3.) Use Longer Transit Times

4.) Avoid Penalties By Using The Right Carrier

5.) Choosing The Best Shipping Insurance

6.) Use Fixed Price Shipping Services When Possible

7.) Decide If Signature Will Be Required On Delivery

Carriers Compared When Shipping Heavy Items

The most cost-effective way to ship large packages will ultimately vary depending on the size, weight, and distance the package will need to travel.

For example, let’s take a look at a parcel that measures 30 inches in length, width, and height and weighs 45 pounds and is going to be traveling from Chicago to New York. 

Using Shippo, you’ll find that your cheapest option would be to use UPS Ground. 

Taking that same example, if we change the package size to 8 inches on each side and the package only weighs 15 pounds your cheapest option would be to use USPS Priority Mail. 

Typically, your least expensive option for shipping heavy packages will be with UPS. However, if you have volume discounts from USPS or pre-negotiated rates with them, then that might be the cheaper option. The best method to ensure you get the least expensive rate on your heavy package is to compare rates from multiple carriers.

That also includes comparing rates from regional carriers as well as international carriers if your e-commerce business ships to countries beyond just the U.S. Because of supply chain delays being felt around the world, you may see even better rates when adding regional and international carriers into your carrier-mix.

Shipping Heavy Items With Shippo

After you weigh your package, you’ll want to weigh your options when it comes to shipping. 

With Shippo, you’ll have access to the best rates with the most carriers no matter how heavy your packages are. You simply have to input the dimensions and weight of your item as well as origin and destination of your package to begin comparing discounted rates from the most trusted names in the shipping industry. 

You’ll also have access to features like:

Sign up for free today and begin creating discounted shipping labels in minutes.

Looking for a multi-carrier shipping platform?

With Shippo, shipping is as easy as it should be.


  • Pre-built integrations into shopping carts like Magento, Shopify, Amazon, eBay, and others.
  • Support for dozens of carriers including USPS, FedEx, UPS, and DHL.
  • Speed through your shipping with automations, bulk label purchase, and more.
  • Shipping Insurance: Insure your packages at an affordable cost.
  • Shipping API for building your own shipping solution.

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