You need to get heavy items to your customers as quickly and efficiently as possible, but you don’t want high shipping costs eating up your profit margin. Shipping costs for bulky or large items can easily add up—but they don’t have to.
The following guide gives you effective strategies for reducing shipping costs on heavy items, like TVs or skis. You’ll also get a handy list of steps to calculate shipping costs, including:
How to calculate dimensional weight
Additional fees and costs to factor in
Tools to cross-check shipping rates
Let’s get started on helping your business reduce shipping costs.
Strategies to reduce shipping costs for heavy items
From the packaging you use to shipment timing and warehouse placement, you have plenty of options to consider for lowering shipping costs. These strategies are some of the most effective ways to keep shipping costs from taking up too much of your budget.
Optimize your packaging
The packaging you’re using could be causing you to pay more for shipping heavy items. Reduce the size and/or weight of your packaging as much as possible to help lower shipping prices. We recommend the following strategies:
Using lightweight materials, such as corrugated cardboard or poly mailers
Getting the right size packaging for your products to avoid using boxes that are too big
Using protective yet efficient packing materials, such as bubble wrap, molded foam, or fiber interior packaging, to avoid damage claims
Work with a 3PL to negotiate with carriers
Third-party logistics (3PL) companies can help you access more competitive rates when shipping heavy items. These companies often have connections with more carriers, providing you with more options—and a better chance at saving money on shipping.
PRO TIP: 3PLs can also combine shipping volumes from all of their clients in order to get better deals.
You can negotiate rates with carriers yourself as an ecommerce business owner, but keep in mind that discounts are typically volume-based. So if you don’t have significantly high volume, you may not qualify for much price reduction. That said, these strategies are a good place to start:
Build strong relationships with shipping carriers to secure volume-based discounts, so you save money when you ship higher volumes.
Research multiple carriers to compare rates and leverage competition.
Negotiate for waivers on additional fees, such as fuel surcharges or special handling.
Gather data on market rates, taking into account factors like fuel costs and carrier capacity.
Red Stag Fulfillment can help you access more cost-effective shipping rates and ship heavy or bulky items more efficiently, thanks to our:
Expertise in warehouse efficiency and packaging optimization
Pre-negotiated rates with major carriers for large/heavy shipments
Guaranteed on-time shipping and accurate orders
Zero-shrinkage policy
Consider flat-rate or regional shipping options
If you’re shipping heavy items that are within certain weight limits, flat-rate shipping can help you keep costs down. Flat-rate shipping has fixed costs regardless of how much your packages weigh—as long as they fall within the specific carrier’s weight limits.
For example, the USPS Flat Rate commercial pricing for shipping a large box (up to 12 ¼” x 12 ¼” x 6”) is roughly $23. Note that flat rate prices vary by type and size of packaging, and these rates are only available for packages weighing up to 70 pounds.
UPS and FedEx also offer flat-rate shipping, but both have an upper weight limit of 50 pounds.
If you’re shipping heavy items across shorter distances, a regional carrier may offer a more cost-effective alternative. These carriers can offer lower rates due to lower overhead costs and operating expenses compared to national and international carriers.
For example, OnTrac reaches over 70% of the U.S. in 35 states and D.C. and offers cost savings of up to 35%. Weekend deliveries are also available at no extra charge, saving you even more money.
Consolidate shipments
Shipping heavy items individually is going to lead to higher costs overall. But finding ways to consolidate these shipments helps reduce prices. For example, you might combine multiple orders that you’re shipping to the same region, rather than sending each one separately.
Using zone skipping may be an option for sending bulk shipments to distribution centers. Instead of having shipments go through multiple shipping zones—driving up costs—they’re sent right to distribution centers.
You might also consider ways to encourage customers to place larger purchases, such as setting order minimums. This helps you avoid having to pay higher costs for shipping several individual packages.
Use strategic warehouse placement
Your warehouse locations can make a significant difference in how much shipping costs for heavy items. Having just one warehouse, for example, means that your products have to travel through different zones to reach it. Having warehouses in a few or more locations cuts down on these costs. So consider using distributed warehousing to reduce shipping zones.
Placing warehouses near major customer concentrations is another smart and efficient move for reducing shipping costs. Heavy items you ship travel shorter distances to reach customers, rather than traveling across the country or to another region.
Choose warehouse locations that offer good access to carriers, so you can build connections and negotiate competitive shipping rates.
Consider dimensional weight pricing
Shipping rates aren’t always based on how much a package weighs. Dimensional weight pricing is based on how much volume or space a package takes up. For example, shipping a smaller, lightweight item in a larger box means you’ll have higher shipping costs with dimensional weight pricing.
To reduce this pricing for heavy items, design products to minimize the amount of space they take up whenever possible. If you can easily reassemble items, break them down before shipping to reduce their volume.
If you’re shipping oversized items, redesigning them to take up less space or breaking them down may not be practical options. But you may want to consider using freight aggregators to cut down on dimensional weight pricing. These aggregators connect you with multiple carriers to help you compare prices and get better rates.
Leverage technology
As an ecommerce business owner, you’re used to relying on technology for processing orders, managing inventory, and other tasks. But you can also leverage digital tools to reduce shipping costs on large or bulky items.
Route optimization software can help you find the most cost-effective and efficient routes from your warehouses or distribution centers to customer addresses. Using these tools helps decrease shipping costs—while also boosting on-time deliveries and customer satisfaction.
Comparing shipping rates from multiple carriers can be time-consuming. But real-time rate shopping software offers a convenient way to compare prices across carriers and find the best rates for shipping heavy items. You can even automate carrier selection based on cost and/or delivery time needs.
Time your shipments strategically
Making changes to when you send shipments of bulky or heavy items can also help you cut down on shipping costs. If possible, ship during off-peak seasons when rates tend to be lower. Even if you can only do this with some items, it helps keep costs lower overall.
Explore carrier promotions to see what kinds of deals and discounts different carriers are offering. For example, you might be able to get a discounted rate when you ship over a certain amount. Check for seasonal deals and discounts for new carrier customers, too.
If you don’t need to send heavy items in a hurry, consider using slower shipping options. These options typically offer lower rates than faster options, making them a cost-effective way to ship non-urgent items.
Join shipping associations
Being part of a shipping organization has its perks—some of which help you reduce shipping costs. The International Trade Association recommends exploring trade associations for specific products (based on what you sell) to find the most suitable groups.
A few examples of shipping organizations include:
Partnering with shipping groups provides access to group discounts. You’re able to pool resources to achieve higher volumes and have better negotiating power with carriers.
As a member, you might also have the option to share trucks or containers with other shippers. This helps reduce the amount your company spends on transporting heavy items to their destinations.
Invest in packaging engineering
Taking a closer look at your packaging can help you find ways to lower shipping costs. Packaging heavier or larger items can be a challenge. You want your items to arrive safe and sound—but you don’t want to pay top dollar to ship each one.
Consider bringing in professionals to analyze and optimize your packaging for you. These experts can determine the right size, material, and other factors to keep packaging cost-effective, safe, and reliable for your company.
You can also do some experimenting on your own to find the best packaging. Test different materials and configurations to figure out which packaging suits your items best, while also helping you keep shipping costs down.
If you have unique items to ship, explore custom packaging solutions. These solutions can help you keep volume or dimensional weight pricing down if you’re shipping large but lightweight items, such as skis.
How to calculate shipping costs for heavy items
As promised, the following steps will help you accurately calculate the cost of shipping heavy items. Note that specific costs and fees for bulky or heavy items can be complex, so it’s best to contact carriers for exact prices. To calculate these costs:
01
Determine the item’s actual weight and dimensions.
02
Calculate dimensional (DIM) weight based on each carrier’s guidelines using the formula Length x Width x Height / DIM divisor (this varies by carrier).
03
Compare the actual weight vs. DIM weight and use the higher value to calculate shipping costs.
04
Add special handling or surcharge shipping fees, such as fees for fragile items or bulky items.
05
Research each carrier’s rates using online calculators, such as the UPS calculator or FedEx Rate Calculator.
06
Include packaging costs and any negotiated discounts to estimate your total cost.
Why shipping heavy items is costly
There are a few main factors that drive up shipping costs for bulky or heavy items. Understanding which factors are impacting your shipping costs helps you develop strategies to reduce expenses.
Weight-based pricing: Carriers charge higher rates for heavier items, often exceeding the standard threshold.
Dimensional (DIM) weight pricing: If you ship large but lightweight items, you’ll pay more for these packages (despite lower weights), since they take up more space or volume. Try out Red Stag’s DIM weight calculator to see how this pricing may affect your shipping costs.
Special handling fees: Shipping fragile or bulky items that require specialized handling comes with higher carrier charges.
The table below gives you an idea of what different carriers charge to ship heavy items within the U.S.
| details | USPS | UPS | FedEx | DHL | OnTrac |
|---|---|---|---|---|---|
| cost | $26 (for large flat-rate box) |
$27 (UPS Ground for large box) |
$28.50 (Express Saver or 2-Day for large box) |
$186 (for 70-lb package in large box) |
$28 (OnTrac Ground for large box) |
| max weight | 70 lb | 50 lb | 50 lb | 150 lb | 50 lb |
Common challenges of shipping heavy items (and solutions)
Costs are just one challenge when you need to ship heavy or bulky items to customers. So let’s take a look at some of the more common issues you might face, along with helpful solutions.
High carrier fees
The cost to ship packages, including heavy ones, is on the rise. In fact, FedEx and UPS raised rates by an average of 5.9% in 2025, and USPS is also proposing rate hikes. With DIM weight pricing, this could lead to carrier fees that are even higher than what you’ve been paying.
DIY Solution: Optimize packaging dimensions to keep DIM-based charges lower, then compare and negotiate rates among multiple carriers to find the best rates for specific weights and destinations.
Professional Solution: Take advantage of pre-negotiated, volume-based discounts available through shipping associations and 3PL providers.
Risk of damage during transit
Heavy or bulky items have a higher risk of damage due to rough handling, poor loading practices, or insufficient packaging. That costs your company in terms of having to replace broken or damaged items for customers.
DIY solution: Use durable, high-quality packaging materials, such as double-wall corrugated boxes, foam inserts, air pillows, or bubble wrap, to protect items. Choose packaging based on product fragility, such as using corrugated boxes for heavier items and air pillows for items that need better shock absorption.
Professional solution: Partner with 3PLs that specialize in heavy-item logistics and use tailored handling practices to prevent damage to your items.
Limited carrier options
Many shipping companies don’t handle heavy shipments. Those that do may charge excessive rates for shipping these items, leaving your business with limited options—and higher shipping costs.
DIY solution: Look into regional carriers to find more cost-effective solutions for shipping over shorter distances.
Professional solution: Partner with a 3PL like Red Stag Fulfillment to access specialized carrier services for shipping heavy or large items.
Complex shipping regulations
If you’re shipping heavy items internationally, you may have to deal with complex regulations when it comes to dimensional limits, weight restrictions, and compliance requirements. This can lead to shipment delays and higher costs.
DIY solution: Research the specific rules and regulations each carrier has for international shipments on heavy items to avoid unexpected fees or delays.
Professional solution: Partner with a 3PL that has experience in compliance management to handle documentation and ensure a smooth international shipping process.
High storage and warehouse costs
Storing heavy or bulky items in a traditional warehouse can lead to increased costs, since these items require more space and equipment.
DIY solution: Use digital tools to optimize inventory management and avoid overstocking large or heavy items in your warehouse.
Professional solution: Work with a 3PL like Red Stag Fulfillment to get specialized storage for heavy and bulky items at competitive rates.
Invest in smart strategies to reduce shipping costs with Red Stag Fulfillment
Shipping heavy items might be unavoidable, but the growing costs don’t have to eat away at your bottom line. The strategies we’ve outlined, like optimizing packaging, using the right technology, timing shipments for savings, and working with a 3PL provider, can help you keep shipping costs lower without impacting customer satisfaction.
At Red Stag Fulfillment, we specialize in handling and shipping heavy or bulky items. We have the experience, connections, and tools to get your products to their destinations quickly, safely, and cost-effectively.
Reach out for more information on our affordable 3PL services.
