What is the difference between Actual Weight and Volumetric Weight?

Actual weight is how heavy the package is on a scale. Volumetric (or Dimensional) weight is a calculation based on the package size (L x W x H). Carriers charge you based on whichever number is HIGHER.

What divisor should I use? 5000 or 6000?

It depends on the courier. For Express Air (DHL/FedEx), the standard divisor is 5000. For Economy Air or Sea Freight (LCL), it is often 6000. Always ask your freight forwarder which formula they use before booking.

Does vacuum sealing really save money?

Yes, massively. For plush toys, pillows, or clothing, vacuum sealing can reduce the volume by 70%. This can turn a $5,000 shipping bill into a $1,500 bill.

Volumetric Weight Calculator: How to Avoid Surprise Shipping Fees

You found a supplier for large plush pillows. They weigh only 500 grams. You did the math: 500g is cheap to ship. You placed the order.

Then you got the freight bill. It was 10x higher than you expected. Why? Because you were charged for Air, not weight.

In logistics, space is money. A plane full of feathers weighs very little, but it is still full. Airlines cannot charge only by weight, or they would go bankrupt shipping pillows.

In this guide, we will explain the "Chargeable Weight" formula and how you can save thousands of dollars by shrinking your packaging by just a few centimeters.

The Concept: Chargeable Weight

Freight forwarders look at two numbers:

Gross Weight (Actual): How heavy it is on a scale.
Volumetric Weight (Dimensional): How much space it takes up.

The Rule: You are charged based on whichever number is HIGHER. This higher number is called the "Chargeable Weight."

The Formula (Air Express)

For DHL, FedEx, and UPS Express, the standard divisor is 5000.

(Length x Width x Height in cm) / 5000 = Volumetric Weight (kg)

Example: The Pillow Problem

Actual Weight: 0.5 kg
Box Dimensions: 50cm x 50cm x 20cm

Calculation: (50 * 50 * 20) / 5000 = 10 kg.

Result:
Actual: 0.5 kg
Volumetric: 10 kg
You Pay For: 10 kg.

If the shipping rate is $8/kg, you expected to pay $4. You actually pay $80. This destroys your profit margin instantly.

Sea Freight vs. Air Freight Formulas

The formula changes depending on the shipping method.

Air Express (Fast): Divisor is 5000. (Most expensive for volume).
Air Economy (Slow): Divisor is often 6000. (Slightly better).
Sea Freight (LCL): Calculated by CBM (Cubic Meter). Generally, 1 CBM = 1,000 kg.

If you have a light, bulky product (like a pillow), Sea Freight is almost always the only profitable option because the penalty for volume is much lower than air freight.

3 Ways to Reduce Volumetric Weight

You cannot change the weight of the product, but you can change the volume.

1. Vacuum Packing

For textiles (plush toys, hoodies, blankets), ask your supplier to vacuum seal the items. This removes all the air.
Result: A 10kg volumetric pillow might shrink to 1kg volumetric.

2. Nesting & Disassembly

If you sell plastic bowls, stack them. If you sell a chair, ship it disassembled (flat pack).
IKEA Strategy: IKEA is successful because they mastered flat-packing. They don't ship "Air."

3. Optimize Master Carton Size

Sometimes the product box is small, but the "Master Carton" (the big box holding 50 units) is inefficient.
If there is empty space inside the Master Carton, you are paying to ship that empty space. Ask your supplier to use a custom-fit Master Carton that hugs the products tightly.

The "Packaging Design" Audit

Look at your product packaging box. Is there empty space inside?

Apple reduced the size of the iPhone box by removing the charger and headphones. While controversial, this allowed them to fit 70% more iPhones on a single shipping pallet. This saved them millions in logistics.

Action: Can you make your box 1cm shorter? On 10,000 units, saving 1cm could save you $5,000 in freight.

FAQ

Do couriers round up?

Yes. They round up to the nearest 0.5 kg. If your package is 1.1 kg, you pay for 1.5 kg.

How do I know the dimensions before ordering?

Ask your supplier for the "Packing List" estimation. Ask specifically for:
1. Dimensions of the Master Carton.
2. Gross Weight of the Master Carton.
3. How many units per Master Carton.
Do the math yourself. Do not trust their quote blindly.

Does Amazon FBA charge volumetric weight?

Yes. Amazon fulfillment fees are based on size tiers. If your product packaging bulges out by 1 inch, it might bump you into the next size tier (e.g., Small Standard to Large Standard), increasing your fee by $1.00+ per unit.

Conclusion

Logistics is a game of millimeters.

Never calculate profit based on the product weight alone. Always ask for the box dimensions. If you are importing light, bulky items, assume the shipping cost will be based on volume, not weight.

Action Step: Go measure your product box. Calculate (L x W x H) / 5000. Is this number higher than the actual weight? If yes, you are paying an "Air Tax." Can you redesign the box to reduce it?

Shipping Weight vs. Volumetric Weight: The Cost Killer You Didn't Know