Amazon Raises FBA Box Size Limit: What Sellers Need to Know (June 2025 Update)

If you sell on Amazon FBA, you know that compliance is everything. One misstep with packaging or labeling can cost you delays, chargebacks, or even account flags. That’s why a recent change from Amazon—effective June 20, 2025—is turning heads across the seller community.

Amazon has updated the maximum box size allowed for FBA shipments, giving sellers greater flexibility and efficiency when prepping and shipping inventory.

Let’s unpack the details of this change, what it means for your business, and how you can turn it into a competitive advantage.

🛏️ What Exactly Changed?

Old Rule: Boxes could not exceed 25 inches on any side for standard-sized FBA shipments.

New Rule (as of June 20, 2025):

• Maximum length increased to 36 inches

• Width and height limits remain at 25 inches

This change applies specifically to standard-size FBA shipments—oversize and special handling categories follow separate rules.

For many sellers, this increased length is a game-changer.

✅ Why This Change Matters

1. Fewer Boxes = Fewer Headaches

If you sell long items (e.g., curtain rods, yoga mats, rolled posters), you likely had to split shipments into multiple boxes to comply with the old 25-inch rule. Now, you can consolidate more SKUs into a single carton.

This simplifies:

• Labeling

• Palletization

• Documentation

And reduces:

• Handling fees

• Labor hours

• Split shipment errors

2. Dimensional Weight Optimization

Dimensional weight pricing penalizes sellers who ship bulky, lightweight items. By allowing longer (but not necessarily larger-volume) boxes, Amazon gives sellers more control over how inventory is packed.

Smarter packaging = fewer boxes = lower costs.

3. Better Warehouse Flow

On the Amazon side, this update allows FCs (fulfillment centers) to move, scan, and receive your shipments faster.

On your side, especially if you use a 3PL like West Coast Prep 3PL, it enables:

• Faster carton prep

• Consolidated box labeling

• Simplified shipping manifests

💡 How to Adjust Your Workflow

Here are five practical ways to make the most of this rule change:

✏️ 1. Audit Your Products

Look at your catalog. Are there SKUs longer than 25" that you had to break up across multiple boxes? Now is the time to reconsider how you package them.

💼 2. Revisit Your Prep SOPs

Update your standard operating procedures (SOPs) for carton dimensions. Inform your prep team or 3PL partners of the new limit. Ensure they adjust polybag, labeling, and bundling workflows accordingly.

⏰ 3. Test with Low-Risk SKUs First

Don’t overhaul everything at once. Identify one or two SKUs that can benefit most from the longer length limit and run a pilot shipment. Monitor how quickly it’s received and whether any issues arise.

📱 4. Communicate with Your Freight Partners

Some LTL or SPD carriers charge surcharges for longer boxes. Make sure your logistics partner is aware of the new limits and aligns pickup methods accordingly.

📊 5. Use Technology to Track It All

Leverage your WMS or dashboard to track how the change impacts:

• Cost per unit

• Receive time

• Inbound compliance

The benefits should show up quickly—in both your metrics and your margins.

🔧 Strategic Advantages for Wholesale & Private Label Sellers

Wholesale sellers can now build mixed-case packs with more SKUs per box. Private label brands can include longer inserts or marketing material in a single box rather than breaking it into separate units. Multi-pack bundling becomes more efficient. And shipping fragile or long products is now far more manageable.

If you work with a prep center that understands how to fully utilize Amazon’s evolving policies, you’re positioned to:

• Reduce shrinkage and damages

• Lower chargeback risks

• Scale more efficiently

✉️ Final Thoughts: Turn This Change into Profit

Amazon doesn’t make FBA changes lightly—when they do, it’s usually in response to operational friction or seller feedback. This is your chance to use a compliance shift to your advantage.

If you’re working with a knowledgeable 3PL like West Coast Prep 3PL, these adjustments can be implemented seamlessly into your fulfillment flow.

Longer box limits mean:

• Fewer shipments

• Better efficiency

• Lower cost-per-unit

All of which translate to higher profits and stronger seller metrics.

Stay sharp. Ship smarter.

Want help adjusting your prep systems to align with the new box limit? Contact West Coast Prep 3PL for support, audits, or fulfillment strategy.