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Double (Over) Boxing Method
What is Double (Over) Boxing?
Double (over) boxing is an effective method of safeguarding fragile equipment like electronics from damage. While using a single box or the original manufacturer's packaging is possible in some instances, there are many situations when this shipping method is ill-advised. Many single boxes are not designed to endure the shipping process, which includes sorting impact, over-the-road vibration, and other kinds of package handling situations. The original equipment manufacturer's package is usually designed to ship the product once, and not multiple times. Even then, it is often designed for shipments on pallets, not single-piece shipments.
How to Double (Over) Box
  • Make sure that the original packaging is in good condition and that the internal foam is not cracked or broken. If the foam is broken, replace with new foam inserts or repair with two-inch (5.08 cm) wide pressure-sensitive tape. It is important that the shipment cannot move within the original manufacturer's shipping container.
  • Select a new shipping container that is at least six inches (15.24 cm) longer, wider, and higher than the original manufacturer's box.
  • Fill the bottom of the new shipping container with at least two to three inches (5.08 to 7.62 cm) of foam-in-place, polyethylene corner or edge pads, inflatable packaging, loose fill peanuts, or other suitable dunnage materials.
  • Place the original manufacturer's box on top of the cushioning material and in the center of the shipping container, allowing for at least two to three inches (5.08 to 7.62 cm) of cushioning around the remaining five sides of the package.
  • Fill the remaining empty space in the package with foam-in-place, polyethylene corner or edge pads, inflatable packaging, loose fill peanuts, or other suitable dunnage materials.
  • Seal the shipping container with either two inches (5.08 cm) or more width of pressure-sensitive or nylon-reinforced tape, or 60-pound, three-inch (7.62 cm) wide water-activated reinforced tape. Close the box securely, applying three strips of tape to both the top and bottom of the box, so the middle and two edge seams are sealed.

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