Why FBA Prep Compliance Matters More Than Ever
Starting January 2026, Amazon officially stopped providing product prep services for FBA sellers. That means everything (labeling, polybagging, bundling, compliance) is now 100% on you. Products arriving at Amazon FCs non-compliant will be rejected, delayed, or disposed of at your expense.
This checklist covers every requirement so your shipments pass inspection the first time.
Amazon Packaging Requirements at a Glance
The short version first. Each row is covered in detail in the checklist below.
| REQUIREMENT | AMAZON'S RULE | MOST COMMON MISS |
|---|---|---|
| Unit label | One scannable FNSKU barcode per sellable unit, on a flat surface, with old UPCs covered | Label on a seam or curve, or a second barcode still scannable |
| Poly bags | Transparent, at least 1.5 mil, sealed, with a suffocation warning when the opening is 5 inches or more | Missing suffocation warning |
| Fragile items | Bubble wrapped or boxed so the unit survives a 3 foot drop | Wrap covering the barcode |
| Sets and bundles | Sold as set or Do not separate label, one FNSKU on the outside, inner barcodes covered | Inner UPCs left scannable |
| Expiration dates | Printed on each unit in MM/DD/YYYY or MM/YYYY format | Stock sent in too close to its date |
| Shipping boxes | 25 inches max on any side, 50 lb max, new or like-new cartons, old labels removed | Overweight cartons |
| Void fill | Air pillows, full sheets of paper or bubble wrap | Packing peanuts or shredded paper |
| Pallets | 40 x 48 inch pallets, 72 inches max height, 1,500 lb max, a pallet label on all four sides | Labels on one side only |
The Complete FBA Prep Checklist
1. Labeling Requirements
FNSKU labels (mandatory for commingled-off sellers):
Every sellable unit must have a scannable FNSKU barcode
Label must be placed on a flat surface, not on a seam or curve
Must not cover any existing manufacturer barcodes (cover old UPC with opaque label or sticker)
Minimum label size: 1" × 2" (standard) or 1" × 3" (preferred)
Print quality must be high. Smudged or wrinkled barcodes will be rejected
Suffocation warning labels:
Required for all poly-bagged items with opening larger than 5"
Warning text: "WARNING: To avoid danger of suffocation, keep this plastic bag away from babies and children. Do not use this bag in cribs, beds, carriages, or playpens. This bag is not a toy."
Minimum font size: 24pt for bags 60" or longer, smaller text for smaller bags
Must be clearly visible and legible
2. Packaging Requirements
Poly bagging:
Required for items that could be damaged by dust, dirt, or liquids
Required for items with loose parts
Bag must be sealed (heat seal, adhesive strip, or tape)
Bag must be transparent
Minimum thickness: 1.5 mil (most common: 2 mil)
Include suffocation warning if opening is larger than 5"
Bubble wrap:
Required for fragile items (glass, ceramics, electronics)
Item must be fully wrapped with at least 2 layers
Must pass a 3-foot drop test without breaking
Wrap must not obscure the scannable barcode
Shrink wrap:
Used for multi-packs and bundles
Must be tight and uniform
Bundle must clearly indicate unit count (e.g., "Sold as set, do not separate")
Each individual unit within the bundle must have its own barcode covered
Overboxing:
Required for items in packaging that won't protect them during transit
Must use corrugated cardboard
Item must fit snugly, no excessive movement inside the overbox
FNSKU label goes on the overbox exterior
3. Product-Specific Requirements
Liquids:
Must be double-sealed (cap + induction seal or tape)
Must be placed in a sealed poly bag
Must pass orientation: won't leak if turned upside down or on side
Glass containers must be bubble-wrapped AND poly-bagged
Supplements & consumables:
Must have clear expiration dates visible without opening packaging
Expiration date format: MM/DD/YYYY or MM/YYYY
Products within 90 days of expiration will be rejected
FDA registration may be required for the storage facility
Apparel:
Must be poly-bagged (protects from dust and moisture)
Hangers must be removed
Size/color labels must be visible through the bag
FNSKU label goes on outside of poly bag
Sharp items:
Must be fully enclosed in protective packaging
Blades must be sheathed or covered
Package must prevent injury during handling
Sets and bundles:
Must be clearly labeled "Sold as set" or "Do not separate"
All individual items must be physically attached or contained together
Only ONE FNSKU for the entire bundle on the exterior
Cover individual UPC barcodes to prevent mis-scanning
4. Box and Shipment Requirements
Carton-level requirements:
Maximum weight: 50 lbs per box (strict)
Maximum dimensions: No single side longer than 25"
Use new or like-new corrugated boxes (Amazon will reject damaged boxes)
Remove or cover ALL old shipping labels and barcodes
Use 2" or 3" packing tape on all seams
No packing peanuts or shredded paper as void fill (Amazon prohibits these)
Acceptable void fill: air pillows, full sheets of paper, bubble wrap
Box content labels:
Each box must have an Amazon shipment label (FBA box ID label)
Labels must be on a flat surface, easily scannable
If using Amazon's box content information, each box must match what's declared
Discrepancies between declared and actual content will cause receiving delays
Pallet requirements (LTL/FTL shipments):
Standard GMA pallets: 40" × 48" only
Maximum pallet height: 72" (including pallet)
Maximum pallet weight: 1,500 lbs
Stack boxes neatly, no overhang
Stretch wrap each pallet with at least 3 layers
Place pallet labels on all 4 sides
5. Common Rejection Reasons
The top reasons Amazon rejects FBA shipments:
Missing or unscannable FNSKU labels
Missing suffocation warnings on poly bags
Products not properly secured (loose items in box)
Wrong item count vs. what's declared
Expired or near-expiration products
Old shipping labels not removed from boxes
Boxes exceeding weight or dimension limits
Using prohibited void fill materials
What happens when products are rejected:
Best case: Amazon sends them back to you (at your expense)
Worst case: Amazon disposes of them
Either way: delayed inventory availability, missed sales, and potential account health warnings
How to Pack an Amazon FBA Shipment, Step by Step
The checklist covers what each unit and box has to look like. This is the order the work happens in, from bulk cartons on your dock to the carrier pickup. Finish the unit prep before anything goes into a shipping box, because a sealed box has to be opened again to fix a missing label.
| STEP | WHAT TO DO | WHAT TRIPS SELLERS UP |
|---|---|---|
| 1. Pick the packing type | Case packed means every box holds one SKU in the same quantity. Individual units means boxes with mixed SKUs or mixed quantities. You choose one when you create the shipment in Send to Amazon. | Declaring case packs, then packing one box with a different count |
| 2. Prep and label every unit | FNSKU label on a flat surface, poly bags, bubble wrap, Sold as set labels and expiration dates, per the table above | Labeling after boxing, so a few units go out bare |
| 3. Build each box | 25 inches max on any side and 50 lb max. Only a box holding a single oversize unit can go over, and above 50 lb it needs a Team Lift label on the top and sides (Mech Lift above 100 lb) | One heavy SKU pushing a mixed box past 50 lb |
| 4. Enter box contents | Tell Amazon what is in each box in Send to Amazon, by web form, spreadsheet upload or 2D barcode | Skipping it: Amazon counts the box by hand, charges a manual processing fee per unit and receiving takes longer |
| 5. Label every box | One FBA box ID label per box, never copied or reused, on a flat side away from seams, with the carrier label next to it rather than on top of it. Remove or cover old labels | The same box label printed on two boxes |
| 6. Ship small parcel or LTL | Small parcel: each box travels with its own carrier label. LTL or truckload: 40 x 48 inch pallets, 72 inches max including the pallet, 1,500 lb max, a pallet label on all four sides | Cartons hanging over the pallet edge |
Steps 2 to 5 are where prep centers earn their fee. Our FBA prep service in Houston labels and bags every unit, builds the boxes within Amazon's limits, enters the box contents and ships to the fulfillment center, with FNSKU labeling from $0.50 per unit.
How a 3PL Handles FBA Prep
This is a lot to manage, especially at scale. Here's how Asfar Distribution handles FBA prep for our clients:
Our FBA prep process:
Receive your bulk inventory at our Houston facility
Inspect every unit for quality and compliance
Apply FNSKU labels with verified barcode accuracy
Poly bag, bubble wrap, or shrink wrap as required
Add suffocation warnings and "Sold as set" labels
Create optimized box configurations within Amazon's limits
Generate shipment plans and box content information
Ship to Amazon FCs with tracking and delivery confirmation
Turnaround time: Most FBA prep orders are completed within 24-48 hours of receiving your inventory.
Selling merchant-fulfilled too? FBM orders can ship from the same inventory we prep for FBA, so you are not splitting stock between a prep center and a fulfiller. See how we run Amazon FBA and FBM fulfillment from one Houston warehouse.
The Bottom Line
FBA prep compliance isn't optional. It's the price of admission for selling on Amazon. With Amazon no longer offering prep services, the responsibility falls entirely on sellers. Getting it right means your inventory goes live faster, your account stays healthy, and your customers get their orders on time.
If you'd rather focus on selling and let someone else handle the prep, that's exactly what we do at Asfar Distribution. Our team preps thousands of units per week to Amazon's exact specifications.
Need an FBA prep center that checks every box? Asfar Distribution in Houston handles FNSKU labeling, polybagging, bundling, and compliant shipping to Amazon, with 24-48 hour turnaround and zero rejection fees. Get a free FBA prep quote.