Optimizing Air Freight Packaging: Avoid These 3 Costly Mistakes
Volume weight, chargeable weight, or non-stackable surcharges? They may seem like mere technical terms, but they determine the profitability of your air freight shipment. Knowing how to optimally build a pallet and how costs per kilo are calculated is the difference between a sharp invoice and unforeseen fines at the airport. In this article, you will learn everything about the crucial role of air freight packaging in reducing your transport costs. We dive into the calculation of volume weight, the three most expensive packaging mistakes, and the various cost components, so that your logistics run smoothly from now on and you maintain full control over your budget.
From parcel post to air freight? A strategic choice for speed and reach. But beware: strict rules apply in the cargo hold. Inefficient air freight packaging immediately leads to unnecessary costs and puts a major dent in your profit margin.
How are air freight transport costs structured?
Before looking at packaging techniques, it is essential to understand exactly what you are paying for. The final invoice for air freight is built up from various cost components. The most important are:
- Base rate (Freight rate): The price for the transport itself, often expressed as air freight costs per kg.
- BAF (Bunker Adjustment Factor): A fuel surcharge that fluctuates with oil prices.
- Security Fee: Costs for the mandatory security screening at the airport.
- AWB Fee: Administrative fees for drawing up the Air Waybill (the consignment note).
- Customs clearance: Costs for clearing your goods in or out.
By optimizing your packaging, you directly influence the base rate and prevent unexpected surcharges.
Mistake 1: The impact of volume on air freight costs per kg
In an airplane, space is more valuable than weight. Therefore, carriers calculate not only the actual weight but also the volume weight. They always charge the highest of the two: the 'chargeable weight'.
The air freight costs per kg are calculated based on this essential formula:
(Length x Width x Height in cm) / 6000 = Volumetric Weight in kg
A half-empty, oversized box can easily double your costs. You are then literally paying for hot air. The motto for efficient air freight packaging is simple: use the smallest possible, fitting box. Every centimeter you save is pure profit.
Mistake 2: Protruding parts and rejection at the airport
The most common mistake when stacking an air freight pallet? Boxes protruding over the edge (overhang). Even 5 centimeters too much can be a reason for rejection during the scan at the airport, because the pallet will no longer fit into standard aircraft containers.
The consequence is that your shipment is rejected or has to be repacked on the spot. In the latter case, count on a 'repacking surcharge' of €75 to €150 that the handler will pass on to you without mercy.
The solution: Build your pallet as a solid block. Ensure a perfectly straight stack, exactly within the edges of the pallet, without any protruding parts.
Mistake 3: The pitfall of 'non-stackable' pallets
Does your air freight pallet have a rounded top, a pyramid shape, or is the stack unstable? Then nothing can be placed on top of it. The pallet is then labeled 'non-stackable'. This is a notorious surcharge: you occupy the full height of the cargo hold. This wasted space is directly charged to you, significantly increasing your air freight transport costs
The checklist for a perfectly stackable pallet:
- Stack in a bonded pattern: Just like bricks in a wall for maximum stability.
- Flat top: Ensure the top layer is perfectly level.
- Sealing: Wrap the entire pallet tightly with film until it is a single solid unit.
Insider tip: On the Cargoplot platform, you gain direct insight into how these costs compare. You see exactly which costs belong to which part of the journey. That is the difference between strategic planning and paying unnecessarily too much.
Want direct insight into all costs, including any surcharges for your shipment? Compare rates and conditions of reliable carriers in advance via our platform.
Frequently asked questions about air freight packaging and costs
What is the formula for volumetric weight in air freight?
The standard formula is: (Length x Width x Height in cm) / 6000. The result is the volumetric weight in kilograms. Is this higher than the actual weight? Then you pay based on this number.
Why is my pallet being repacked at the airport?
This usually happens due to 'overhang': boxes protruding outside the pallet dimensions. As a result, the pallet does not fit into the scanning equipment or aircraft containers. This leads to extra costs between €75 and €150.
What is a 'non-stackable' surcharge?
This is a surcharge for pallets on which no other cargo can be placed (e.g., due to a pointed shape). You then pay for the full height of the aircraft hold, which drives up the price significantly.
What are the main cost components of air freight?
The costs consist of the base rate (freight), fuel surcharge (BAF), security fees, documentation costs (AWB fee), and customs clearance costs.
How is the air freight price per kg determined?
The price per kg is determined by market forces (supply and demand), fuel prices, and the chosen route. In addition, the ratio between weight and volume (chargeable weight) plays a crucial role.
What is the difference in costs between air freight and ocean freight?
Air freight is significantly faster but also more expensive (often 4 to 6 times the price of ocean freight). Air freight is calculated per kg (or volume), while ocean freight is often calculated per cubic meter (CBM) or per container.
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