6 Tips for selling large & oversized products on Amazon

Selling large and oversized items on Amazon, such as patio furniture sets, exercise equipment, and home entertainment systems, can be incredibly profitable. However, it doesn’t take long for the hidden costs to accumulate.

You’re often dealing with high Fulfilled by Amazon (FBA) fees, expensive storage and shipping, strict packaging and sizing requirements, and complex return logistics. Many sellers find Amazon’s rules around oversized products difficult to understand, leading to costly mistakes and compliance issues.

Because of these challenges, most sellers avoid oversized items entirely—which is where your opportunity lies. If you can plan around the fees, streamline your operations, and deliver a reliable customer experience, you can build a strong and profitable niche with little competition.

This guide will walk you through exactly how to do that. You’ll learn specific, actionable strategies to make oversized items profitable while avoiding the common pitfalls that cut into margins and damage customer trust.

What you’ll learn

Breaking down Amazon’s size tiers

Amazon sorts non-standard products into two broad size tiers—extra-large and large bulky—based on weight, dimensions, and packaging requirements.

Key criteria

Extra-large

If your product meets any of the following criteria, it’ll be classified as extra-large:

*Girth = (median side + shortest side) × 2

For instance, if your item has a median side of 15″ and the shortest side is 10″, the calculation would go as follows:

Additionally, extra-large items are classified into four weight categories based on the greater of their unit weight or dimensional weight:

All extra-large items must ship in their original product packaging as part of the “Ships in Product Packaging” (SIPP) program. In other words, if a product is classified as extra-large, it automatically falls under SIPP.

SIPP, formerly known as Ships in Own Container (SIOC), applies to items shipped in their original manufacturer packaging without additional outer packaging. It’s also worth noting that SIPP usually offers lower fulfillment rates, but only for products under 50 lb, meaning extra-large items are excluded from the discounts.

The product’s packaging must be sturdy enough to withstand last-mile delivery from the distribution center to the customer. In other words, the shipping box must meet Amazon’s safety standards.

This requires using a corrugated box with high burst or crush strength, at least 2″ of cushioning on all sides, and strong packing tape that seals the package securely for its entire journey.

Large bulky

The large bulky tier and the newly defined extra-large tiers have replaced the old oversize and extra-large tiers on February 5, 2024. Your product is classified as large bulky if it’s:

Amazon size tier classification table

For a complete breakdown of Amazon’s size tiers, refer to the following table:

If any single dimension or weight exceeds the limits of a given tier, the entire package is classified in the next larger tier.

For example, if you have a package that weighs 65 lbs, which falls into the Extra-large 50+ to 70 lb tier by weight, but its dimensions are smaller than the tier’s minimum, e.g., are in line with Large Bulky, your package still qualifies as Extra-large 50+ to 70 lb because the weight alone places it in that tier.

Similarly, if any one of the length, width, height, or length + girth measurements exceeds a tier’s maximum allowed measurement, the package must be classified in the larger tier corresponding to that dimension.

Fulfillment by Amazon (FBA) for oversize products

Managing logistics for large products comes with challenges like high shipping costs, complex packaging requirements, and expensive storage space.

Instead of handling all of this on your own—a process known as Fulfillment by Merchant (FBM)—you can use the FBA service instead, which takes care of storing, packing, and shipping oversized products for you.

With FBA, Amazon handles:

For a full breakdown of fees associated with large, bulky items, refer to the official FBA Fulfillment Fees guide on Seller Central.

If you’re unsure whether a product is classified as Dangerous Goods, use Amazon’s ASIN lookup tool (found in Seller Central > Inventory > Manage Inventory) to verify its classification.

Tips for selling large and oversized items on Amazon

Selling large items on Amazon can be tricky, but the right strategy can make it profitable. Here are some tips to get you started.

To avoid unnecessary fees, understand your costs, profits, and how Amazon’s fees impact them.

Start with a full cost breakdown—including production, shipping, packaging, fulfillment, and marketplace fees. Knowing your true cost per unit helps you price effectively and protect your margins. Here are some major cost considerations:

Once you have an estimated cost for each product, add your desired profit margin to get a rough idea of how much your product should cost once you list it.

A proven way to save money on shipping and storage fees is to optimize your packaging strategy.

Packaging best practices

While it may seem counterintuitive, investing in higher-quality packaging materials for heavy items can reduce shipping costs. Durable foams and molded inserts provide better protection with thinner, lighter layers compared to bulkier, cheaper options. This results in smaller, lighter packages that qualify for lower shipping tiers and lower dimensional fees.

Reducing package size and weight directly lowers shipping costs. Better protection also means fewer damages and returns, saving money and preserving customer satisfaction.

While all extra-large items now ship in their own product packaging and don’t receive special fee reductions, there are still ways to benefit from this.

Using robust packaging reduces the need for additional outer cartons, which can simplify handling and reduce packaging costs without compromising on protection.

To optimize the process, work with packaging engineers and suppliers to design SIPP-compliant packaging that provides adequate padding and protection for various shipping conditions.

Shipping options

When shipping to Amazon warehouses, you have two main options: standard shipping for smaller orders and freight shipping for larger shipments. Freight shipping, particularly less-than-truckload (LTL), is typically cost-effective for high-volume shipments because it combines multiple products into a single shipment, thereby reducing costs.

If you use FBA, an excellent way to save on shipping large boxes is by enrolling in Amazon’s Partner Carrier program, which offers discounted rates and easy booking for both parcel and freight shipments.

Those using FBM with a freight forwarder may find better or similar cost savings with LTL or pallet shipments compared to FBA freight.

Fulfillment: FBA vs. FBM

Fulfilling orders on Amazon comes down to two main options: FBA and FBM. Each has trade-offs in cost, convenience, and control.

FBA takes care of the entire fulfillment process—picking, packing, shipping, returns, and customer service. It’s convenient, especially for high-volume sellers, and offers lower base storage fees for oversized items. However, those savings can be offset by accumulating storage and long-term inventory charges.

FBM gives you more control over costs by allowing you to manage your own packaging and shipping. It’s a good fit for low-volume or slow-moving products, provided you have an efficient fulfillment system or a reliable 3PL partner like Red Stag Fulfillment, who can reduce your shipping and storage costs through optimized logistics.

Ultimately, the best choice depends on your scale, margins, and logistics setup. FBA simplifies operations but comes at a premium, while FBM can be more cost-effective for large items, but only with the right infrastructure in place.

Handling returns for large and oversize items on Amazon requires a strategic approach, as return processing fees are significantly higher compared to standard-size products, even if you use FBM and have a reliable 3PL partner.

The key to minimizing returns begins before the sale. Accurate listings and detailed product descriptions help customers make informed decisions and significantly reduce the likelihood of returns.

If you use FBA, Amazon manages the return logistics, but the fees for oversized items can be substantial due to higher transportation and handling costs. For example, returning heavy or bulky products can incur much greater fees compared to standard items.

For heavy items over 100 lbs, traditional customer drop-off returns are usually impractical. In these cases, enabling Amazon-arranged LTL returns allows for freight pickups.

For FBM sellers, you have control over product return logistics, which can help lower costs, provided you have a well-established system in place. Efficiently managing returns involves inspecting items, restocking inventory, and handling customer service, all of which are easier and more cost-effective with a reliable 3PL partner.

Above all, providing consistent, high-quality customer service is essential. Fast responses, support with delivery setup, and clear post-sale communication not only enhance the customer experience but also help reduce return rates.

Amazon offers various resources and cost-saving programs for sellers that help optimize operations, lower expenses, and enhance the overall customer experience.

Free seller tools

Amazon has several free tools to manage your operations more efficiently:

Cost-saving initiatives

Lower your operational expenses with these Amazon programs:

Seller-Fulfilled Prime (SFP)

Seller-Fulfilled Prime (SFP) is an alternative fulfillment method that lets sellers with strong shipping capabilities fulfill Prime orders directly from their own warehouses while still displaying the Prime badge.

This is an excellent solution for sellers who utilize FBM and can meet Amazon’s shipping standards. They can leverage the Amazon Prime branding while maintaining full inventory control. It’s especially beneficial for bulky or heavy products, where FBA fees can be costly.

However, a major downside is that sellers must consistently meet Amazon’s strict standards, including same-day processing and weekend shipping.

Fortunately, you can still qualify for SFP by partnering with a fulfillment provider that understands these requirements and has the infrastructure to support them.

Red Stag Fulfillment, for example, specializes in reliable, accurate handling of bulky and heavy products. We’ll help you maintain the high standards needed to keep the Prime badge and satisfy customer expectations.

Shipping large items requires special attention to both hazardous materials regulations and general safety standards.

Without a clear understanding of these rules, you risk serious consequences, including safety hazards during handling and transport, costly fines for regulatory violations, and shipment delays or cancellations.

We’ll go over the requirements briefly here, but we strongly encourage you to consult official resources and seek expert guidance.

Dangerous goods compliance

Large items that contain hazardous materials, such as batteries, chemicals, or flammable components, must fully adhere to Amazon’s hazardous materials (hazmat) policies. Compliance requires:

Non-compliance can lead to shipment rejection, fines, or legal penalties.

Safe transit practices

If your large item contains hazardous materials, such as lithium batteries, flammable components, and pressurized contents, it must comply with Amazon’s hazmat policies. This includes:

These practices are in addition to standard shipping practices for large or oversized items.

Failure to meet hazmat regulations can result in shipment delays, fines, removal from Amazon’s catalog, or suspension of your selling privileges.

Amazon charges several fulfillment fees that can significantly impact your profit margins if not properly accounted for. Before setting your prices, learn more about these key cost drivers to avoid surprises and maintain profitability.

This section primarily covers the major FBA fees and surcharges that affect your margins when using Amazon’s fulfillment network.

For sellers who fulfill orders themselves (FBM), we’ll share some cost-control tips. However, managing expenses largely depends on optimizing carrier rates and handling logistics efficiently, as covered in earlier sections.

FBA cost drivers

FBA fees don’t scale proportionally with size and weight. Even small changes can lead to significant cost increases.

For example, if the longest side of your item increases from 59″ to 61″, it can move from the large bulky tier to the Extra-large 0 to 50 lb tier, leading to significantly higher fees. These costly jumps often happen because:

Maintaining dimensional thresholds and using lightweight materials can significantly reduce FBA fees.

Another major cost is the fee that Amazon charges when shipping items to fulfillment centers.

On April 15, 2024, Amazon introduced an Inventory Placement Service Fee (IPSF) on every shipment you send to FBA. This fee structure is particularly impactful for sellers of large and bulky items, although it doesn’t apply to the Extra Large category.

To help manage this fee, Amazon offers three shipment split options, each with different cost implications:

The way you distribute your inventory across Amazon’s fulfillment network can significantly impact costs. Shipping to multiple centers reduces and can even eliminate placement fees, but it also increases upfront packing and shipping costs.

If you’re dealing with bulky items, sending to five or more centers eliminates the IPSF, but watch out for higher storage fees with slower-moving stock.

For slow-moving items, self-fulfillment can be more cost-effective. Alternatively, consider shipping to just a few centers at a time to strike a balance between fees and logistics.

Peak-season surcharge

Amazon’s peak season runs from October to the end of December each year. In this period, expect additional fees for all fulfillment services. While you’re likely to earn more money thanks to the increased seasonal demand, the added costs impact your bottom line.

We recommend reviewing Amazon’s annual peak-season rate card before this period to properly budget for these temporary increases. Having this information readily available helps you avoid unexpected costs and maintain transparent pricing for your customers.

If you use FBM, consider splitting your shipments across multiple carriers to manage peak-season surcharges more effectively. At Red Stag Fulfillment, we offer solutions to help you optimize your shipping strategy during the peak season.

Remote-area delivery surcharge

When shipping to some U.S. states and territories such as Alaska, Hawaii, or Puerto Rico, remote-area surcharges significantly impact costs. For standard parcels, the fee can be 100% of the base fulfillment cost, and for large or extra-large items, it rises to 200%. If you sell to these regions, include these surcharges in your pricing and clearly inform buyers that higher shipping fees may apply.

For FBM sellers, your shipping partners may charge even higher remote-area fees. Since you control the shipping process, compare carrier rates to find the most affordable option and factor these surcharges into your pricing.

Sell your oversized products with confidence

Selling large items on Amazon can be a profitable endeavor with the right approach. By accurately classifying your products and aligning with Amazon’s packaging standards, you can significantly reduce or even eliminate many fees.

Achieving success requires smart packaging design, strategic pricing, and inventory planning aligned with demand. Taking advantage of Amazon’s resources and seller programs can further cut costs and enhance your product’s visibility.

If you’re ready to scale your sales, Red Stag Fulfillment is the ideal partner. We specialize in handling large, heavy, and bulky items, with purpose-built warehouses and advanced equipment that ensure your products are stored and shipped with precision and care.

Don’t let logistics be a barrier to your growth. Reach out today for a custom quote tailored to meet your needs.