Carton or Pallet: What’s Best for Amazon FBA in Australia?

Amazon’s rules for loose carton shipments vs palletised loads in Australia have changed significantly. From 1 September 2025, self-delivered small parcels will no longer be accepted at any FBA fulfilment centre. All cartons must move through approved carriers or Amazon programs.

Australia’s e-commerce logistics sector was valued at $9.87 billion in 2024 and is projected to nearly double by 2033, yet many sellers are already experiencing rejected or delayed shipments as they adapt to Amazon’s updated inbound rules.

This article breaks down when cartons still work, when pallets offer a better path through Amazon’s inbound system, and how to choose the right approach for your next FBA delivery.

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Shipping Pallets vs Boxes in Amazon Australia

Here’s a quick breakdown to help you choose between cartons and pallets under Amazon’s new rules.

• From 1 September 2025, Amazon will no longer accept self-delivered small parcels. All cartons must move through approved carriers or Amazon SEND.
• Cartons work best for lightweight, single-SKU replenishments where the shipment size is small and the handling process is straightforward.
• Pallets suit bulk or mixed-SKU shipments that benefit from fewer touchpoints, faster receiving, and consolidated handling at fulfilment centres.
• Costs rise quickly with carton count due to separate scans, multiple handling events, and volumetric pricing. Pallets consolidate these steps into a single freight movement.
• Shift to pallets when carton volume increases, CBM or weight reaches freight thresholds, or when you need predictable dock-slot scheduling.
• Choose the format that best meets Amazon’s packaging, ASN, and carrier requirements to avoid delays or rejections.

For bulk inbound freight, consider booking full-truck delivery to Amazon fulfilment centres through Couriers & Freight.

What Changed for FBA Inbound in 2025 and Why It Matters

Amazon has updated its inbound delivery rules for 2025, removing the option to self-deliver small parcels to any FBA fulfilment centre. Carton shipments must now move through approved carriers, Amazon SEND, or the Partnered Carrier Program. Otherwise, they are rejected on arrival. This shift affects how sellers plan loose carton shipments vs palletised loads, particularly for time-sensitive or high-volume stock.

Amazon introduced these changes to reduce manual handovers and improve receiving accuracy throughout its fulfilment network. With higher inbound volumes, warehouses need shipments that can be scanned, stored, and processed with fewer handling steps.

What sellers must do differently:

1. Use approved carriers or the Partnered Carrier Program for all carton-sized shipments.
2. Ensure Advanced Shipping Notice (ASNs) and carton labels match exactly before booking a pickup.
3. Book delivery slots early for palletised loads.
4. Check that all cartons and pallets meet Amazon’s size, weight, and labelling requirements.
5. Confirm carrier arrangements before dispatching any small-parcel shipments to avoid rejection.

Across seller discussions online, a clear pattern has emerged: early rejections and delays often occurred when cartons were hand-delivered or when ASNs didn’t match the physical shipment. These real-world experiences highlight why following Amazon’s updated process is critical when deciding between loose carton shipments and palletised loads.

Loose Carton Shipments: When They Still Make Sense

Loose cartons remain suitable for certain types of Amazon FBA inbound deliveries in Australia, particularly when shipment size is small and handling requirements are simple.

When cartons are a practical choice:

• Ideal for low-volume or lightweight items that don’t justify pallet freight.
• Useful when sending quick replenishment stock for fast-moving SKUs.
• Suitable for single-SKU shipments where each carton can be labelled and processed consistently.

Carton size, weight & labelling requirements

• Cartons must meet Amazon’s parcel limits for weight and dimensions published in Seller Central AU.
• Each carton requires a scannable FBA label matching the ASN exactly.
• Labelling must be clear and placed where carriers and fulfilment centres can read it during handling.

Limitations & risks

• Each carton requires its own scan and handling cycle, which increases the likelihood of misrouting, delays or damage during receiving.
• Dimensional weight pricing can raise costs when cartons are large or low-density.
• Carriers apply surcharges when cartons exceed certain size/weight thresholds or when volumetric weight (DIM weight) is high. For example, carriers like DHL in Australia apply dimensional‑weight pricing: “whichever is greater, actual weight or volumetric weight”.
• Forum discussions show a recurring issue: cartons with incorrect labels or mismatched ASNs often experience delays on arrival at fulfilment centres.

When carton freight becomes less efficient:

• Costs increase once shipments include multiple cartons requiring separate handling.
• Higher pickup, scan, and sorting requirements often make loose carton shipments less predictable than consolidated loads.
• Sellers managing repeated replenishment runs or a high number of cartons typically benefit from shifting to palletised loads.

Why More Sellers Are Switching to Palletised Loads

Palletised loads have become the preferred option for many Amazon FBA sellers in Australia, especially as inbound requirements become stricter and volumes increase. A single pallet consolidates dozens of units into one handling event, which aligns better with how fulfilment centres receive and process freight.

Why pallets work well for high-volume or mixed shipments:

• Pallets are lifted as a single unit, reducing the number of scans and touchpoints required during unloading.
• Fulfilment centres can position and store pallets more quickly because the load is uniform and fully wrapped.
• Mixed-SKU shipments are easier to manage when cartons are grouped and stabilised on a pallet.
• Consolidating cartons into one pallet reduces the risk of mis-scans or misplaced items during receiving.

Cost Comparison: Carton vs Pallet (Australia-Specific)

The cost difference between loose carton shipments and palletised loads comes down to how each format is handled during pickup, transit, and receiving. Each carton triggers multiple touchpoints, while a pallet consolidates the load into a single movement.

As shipment volume grows, the total cost of loose cartons escalates because each carton creates separate scans, labels, and handling charges. A pallet, by contrast, moves through carriers and fulfilment centres as one unit, which lowers the number of chargeable events and reduces the likelihood of handling issues.

Across seller discussions, a recurring pattern is that carton freight becomes unpredictable once shipments move beyond a small number of boxes, particularly when dimensional weight pricing or repeated restocks are involved.

This cost pattern becomes even clearer when deciding when to move from loose carton shipments to palletised loads, which the next section covers in detail.

When to Move from Cartons to Pallets

The point at which loose carton shipments stop being practical varies by seller, but several operational triggers consistently indicate when palletising is the more reliable option.

Common thresholds that signal a shift to pallets:

• High carton count: Once shipments involve many cartons, each requiring separate scans and handovers, delays become more likely and pallet freight becomes easier to manage.
• Rising cubic weight: When total CBM or dimensional weight approaches freight classification, consolidating cartons onto a pallet avoids unexpected parcel charges.
• Mixed-SKU shipments: Pallets help group SKUs together, reducing the chance of misplaced cartons during receiving.
• Frequent replenishments: Sellers with regular restock cycles often find a single pallet booking more predictable than multiple parcel pickups.
• Import workflows: When stock arrives in container loads, palletising during unpacking simplifies the move from port to fulfilment centre.

Community feedback shows that once shipments exceed a moderate number of cartons, or when repeated restocks introduce more handling steps, pallet loads generally create fewer issues during check-in.

These thresholds help sellers assess when loose carton shipments vs palletised loads become operationally different, setting up the practical preparation steps covered in the next section.

Prep & Compliance Essentials (Cartons and Pallets)

Preparing shipments correctly is essential for smooth receiving at Amazon’s fulfilment centres. These checklists outline the key requirements for both loose carton shipments and palletised loads, based on Seller Central AU guidelines and common issues shared by sellers.

Cartons

• Apply FBA labels where they are easy for carriers and fulfilment centres to scan.
• Match every carton label to the ASN without exceptions.
• Keep carton weight and dimensions within Amazon’s published parcel limits.
• Use packaging that prevents bulging or distortion, which can cause scanning issues.
• Avoid mixed-SKU cartons unless the contents are clearly marked and allowed under Amazon rules.
• Ensure each carton is sealed firmly so it can withstand multiple handling steps.
• Note from seller discussions: cartons with unclear labels or mismatched ASNs frequently encounter receiving delays.

Pallets

• Build pallets on CHEP, Loscam or approved one-way bases with no carton overhang.
• Wrap the load tightly to stabilise cartons during transit and forklift handling.
• Keep pallet height and weight within Amazon’s limits to ensure safe movement inside the warehouse.
• Place pallet labels on at least two visible sides so forklift operators can scan them without repositioning.
• Group SKUs logically when preparing mixed cartons on a pallet to reduce the chance of putaway errors.
• Check that all cartons on the pallet carry the correct FBA labels and match the ASN for the load.

Booking and Delivery Timing

• Reserve dock slots early for palletised loads, especially during busy periods.
• Confirm carrier appointment references before dispatch.
• Ensure paperwork is complete so the driver can hand over the load without delays.
• Verify weight, dimensions and pallet count with the carrier to prevent refusals on arrival.

Accurate preparation lowers the risk of receiving errors and allows fulfilment centres to process shipments more quickly, regardless of whether they arrive as cartons or pallets.

How Couriers & Freight Helps with FBA Inbound (AU)

Couriers & Freight provides practical support for sellers sending both loose cartons and palletised loads to Amazon fulfilment centres. The service focuses on preparing freight correctly, reducing rework, and ensuring shipments arrive with the right labels, paperwork and booking references.

For palletised freight, Couriers & Freight can build or rebuild pallets during container unpacking, apply the required labels, secure the load to Amazon’s specifications, and organise full-truck delivery to fulfilment centres with the correct dock-slot bookings. This is especially useful for bulk or mixed-SKU shipments that need consistent handling from warehouse to Amazon.

For carton-based shipments, the team can check carton dimensions and weights against Seller Central requirements, fix labelling issues, and coordinate approved carriers under the 2025 inbound rules. This helps avoid the delays sellers often encounter when ASNs or labels don’t match what Amazon expects.

Couriers & Freight also supports mixed inbound workflows, such as unpacking import containers, consolidating cartons onto pallets, or cross-docking goods between suppliers, so freight moves through the supply chain with fewer handovers.

If you’re sending pallets or bulk stock into Amazon’s fulfilment centres, Couriers & Freight can organise full-truck delivery and ensure your shipment arrives prepared and compliant.

Get an instant quote now to streamline your FBA inbound shipments.

Send Pallets Direct to Amazon FBA

Move your bulk stock with full-truck delivery to Amazon fulfilment centres. Get compliant, carrier-ready pallet freight handled by Couriers & Freight.

Get a Quote Now