Packaging Basics: What Is an Overpack Box?

If you haven’t heard the packaging term “overpack,” you might think of a suitcase stuffed to bulging with clothes. But when it comes to hazmat packaging, an overpack is actually one of the most important packaging materials for keeping various types of goods safe and contained.  Overpack packaging is a type of packaging that is used for additional protection when shipping sensitive materials, particularly hazardous goods. It’s an important part of any complete hazmat shipping strategy. Today, we’ll offer a quick overview of why these packaging materials are so important, as well as overpack box options that Air Sea Containers offers for your business.  Jerrican Jug Overpack Kit

10 Liter (2.64 Gallon) Jerrican / Jug Overpack Kit

What Is an Overpack? 

The basic purpose of an overpack is to create an extra layer on top of existing packaging to make it stronger, more resilient and able to contain its contents in case of an emergency. Overpacks are designed to go on top of the primary packaging material and insulate it from rough handling, moisture and the many other hazards that a package can encounter while in transit.  Overpacks come in many shapes, sizes and materials. Some are corrugated shipping boxes, while others are steel or polyethylene salvage drums. Each is suited to providing a different type of protection. Before we talk about the different overpacks available, though, let’s review why these packaging devices are so crucial to hazmat shipping success. 

Why Are Overpacks Important? 

Overpacks are tremendously important for personnel and environmental safety when shipping hazardous materials. Spills and leaks can create hazards where they’re least expected, potentially leading to personnel injuries or environmental damage. The costs of a hazmat spill can be substantial, and every layer of protection added helps make a spill easier to handle and clean up.  Many authorities that regulate hazmat shipping, such as the Department of Transportation, the International Air Transportation Association and the International Maritime Organization, require businesses to use overpack boxes when shipping certain types of goods. Make sure to check relevant rules such as the International Maritime Dangerous Goods Code, IATA Dangerous Goods Code and DOT overpack regulations to ensure that your overpack packaging is compliant with the relevant rules.  Freight carriers such as FedEx, DHL and UPS also often require overpack packaging for certain types of goods. Again, any hazmat shipper that needs overpack boxes should make sure to check their carrier’s regulations before making a purchase, as each may have slightly different rules on which types of overpacks are acceptable.  Finally, overpacks are also useful for consolidating multiple packages into one. Jerricans, for example, can easily be packed in groups of four into a single corrugated overpack box, simplifying shipping and providing protection. Overpacks provide a simple consolidation solution that also improves safety and ease of product handling—a win for everyone.  4 x 5 Liter Jerrican style

4 x 5 Liter (1.32 Gallon) UN Rated Jerrican Overpack Kit

Types of Overpacks

Air Sea Containers offers numerous overpack options for hazmat shippers. All of our overpack packaging is rigorously tested for compliance with relevant IATA, IMO, DOT and UN rules. 
  • Corrugated Overpack Boxes: Some of our most basic and effective overpack options, Air Sea’s corrugated overpack boxes are created from rugged double-walled corrugated board and designed to offer the UN- and DOT-rated protection for your goods. 
  • Overpack Kits: Overpack kits can offer a quick and easy way to safely package hazardous goods. Our kits come with everything you need to get started, including primary packaging like jerricans and 5-gallon buckets, plus overpack stickers to alert handlers. 
  • Salvage Drums: Salvage drums are designed to provide protection against leaking shipping drums. A leaking drum can create a dangerous situation and a costly cleanup, so shippers use salvage drums to safely transport drums that are at risk of leaking and ensure that any spillage won’t escape. 
We can also create custom UN-rated corrugated hazmat shipping boxes for our customers. Just go to our custom corrugated boxes page to see the many options we have available, including four-color printing, a variety of board thickness options and fully customizable styles.  carrying boxes in a warehouse Air Sea is proud to provide an industry-leading selection of overpack box solutions to our customers both inside and out of the hazmat shipping industry. Got more questions about Air Sea’s overpack options? Our packaging experts will be happy to help. Just give us a call at (866) 596-9448 or contact us online

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