How to Package Oversized and Awkwardly Shaped Products

Oversized, long and unusually shaped products can be difficult to protect using standard bags and cardboard boxes. The nearest available size may leave excessive empty space, while forcing an item into packaging that is too small can damage both the product and the container.

Two practical options are cut-to-length layflat tubing and custom cardboard boxes. The right choice depends on the product’s shape, weight, surface and required level of protection.

Start by Measuring the Product

Before selecting any packaging, measure the product in the condition in which it will be packed. Include any bubble wrap, foam profiles, corner protection or other materials that will be applied first.

Record:

• The maximum length, width and height
• The widest point of an irregular product
• The approximate packed weight
• Any projections, handles or sharp edges
• Whether the product can be folded or dismantled

For cylindrical items, measure the circumference or diameter as well as the length. Accurate measurements make it easier to choose tubing that slides over the product or a box that provides enough room for protection.

Layflat Tubing for Long and Irregular Products

Polythene layflat tubing is supplied as a continuous flattened tube on a roll. It can be cut to the required length, allowing businesses to produce individual sleeves or bags as needed.

It may be useful for:

• Carpets, rugs and textiles
• Posters, prints and rolled materials
• Pipes, tubes and long components
• Clothing and soft goods
• Furniture parts
• Awkwardly shaped industrial products

Because the length is selected during packing, one roll can accommodate products of several different lengths without requiring a separate fixed-size bag for each item.

Medium or Heavy-Duty Layflat Tubing?

The current range includes 250g medium-duty tubing and 500g heavy-duty tubing.

Grade	Thickness	Typical Applications
250g medium duty	Approximately 62.5 microns	Clothing, linens, posters, stationery and lighter products
500g heavy duty	Approximately 125 microns	Carpets, bulky goods and more demanding industrial products

The heavier grade provides greater resistance to tearing and puncturing, but it is not puncture-proof. Sharp corners, metal edges and exposed fixings may still require foam, cardboard or another protective barrier.

Choose the lightest grade that can withstand the product and expected handling process. Using thicker film than necessary increases material use without automatically improving the way the item is packed.

How to Choose the Correct Tubing Width

Layflat tubing is measured across the material while it is lying flat. This is not the same as the diameter of the finished package.

The tubing must be wide enough to open around the product at its largest point. Allow additional space where protective wrapping, irregular sections or projecting fittings increase the finished dimensions.

A tube that is too narrow may:

• Be difficult to slide over the product
• Place excessive pressure on the film
• Split around corners or projections
• Compress vulnerable goods

An excessively wide tube may leave loose material, create an untidy pack and require more work to close securely.

How to Create a Custom-Length Bag

1. Measure the product after protective materials have been applied.
2. Select tubing wide enough to pass over its largest point.
3. Cut a section longer than the product to leave space at both ends.
4. Seal or close one end where required.
5. Insert the product carefully without dragging it against the film.
6. Remove excessive loose material.
7. Close the remaining end securely.

Suitable closure methods can include a heat sealer, packaging tape, staples, cable ties or wire ties. The chosen method should suit the contents and expected storage or delivery conditions.

The cable and wire tie range includes different lengths for closing tubing and bags. Avoid fastening the material so tightly that the closure damages the product beneath it.

Does Layflat Tubing Protect Against Moisture?

Polythene tubing can help protect goods from warehouse dust, dirt and light moisture. The effectiveness of that protection depends on the condition of the film and how securely both ends are closed.

It should not automatically be considered completely waterproof or airtight. Water may enter through an unsuitable closure, a puncture or an opening around an irregular product.

Products requiring controlled humidity, complete waterproofing or specialist contamination protection may need another packaging system.

When Is a Custom Cardboard Box More Suitable?

Layflat tubing provides a flexible outer covering, but it does not offer the rigid support or crushing resistance of corrugated cardboard.

A custom cardboard box may be more appropriate when:

• The product is fragile or easily crushed
• Several components need to remain in position
• The package will be stacked
• The product requires internal dividers or inserts
• A consistent box is needed for repeat orders
• Standard box sizes leave excessive empty space

Martins Mill Packaging manufactures custom boxes at its Halifax premises. Boxes can be made to specified dimensions using single or double wall corrugated board, including trial and limited-quantity orders.

Single or Double Wall Custom Boxes?

Single wall cardboard may suit lighter products and routine dispatch. Double wall board provides additional strength for heavier goods, stacking and more demanding handling.

The board type should be selected alongside:

• The packed weight
• The product’s fragility
• The box dimensions
• The amount of internal support
• Storage and stacking conditions
• The delivery journey

A double wall box is not a replacement for suitable cushioning. Fragile goods may still need bubble wrap, paper, foam protection or fitted cardboard inserts.

Can Tubing and Cardboard Be Used Together?

Some products benefit from a combination of materials. An item may be placed inside a polythene sleeve before being packed into a box, helping protect it from dust or light moisture while the cardboard provides structural support.

Other combinations can include:

• Foam profiles around vulnerable edges
• Bubble wrap around fragile surfaces
• Cardboard dividers between components
• Paper or another suitable void fill
• Strapping around heavy outer cartons

The complete package should prevent damaging movement without placing excessive pressure on the product.

Choosing the Best Option

Layflat tubing is generally suited to long, rolled, soft or irregular goods that need flexible cut-to-length protection. Custom cardboard boxes are more appropriate where the product requires rigid support, stacking strength or a repeatable fitted package.

Some oversized products will need both an inner protective layer and a custom outer container. Base the decision on the full packing, storage and transport process rather than the product dimensions alone.

For help selecting a suitable option, contact Martins Mill Packaging with the product dimensions, packed weight, shape and required level of protection.