Amazon Expands FBA Box Size: What Sellers Need to Know

The content of this article covers Amazon’s recent FBA box‐size update, the AWD implications, pros and cons of the change, smart questions to ask, seller feedback, Cahoot’s solution, and FAQs—all in one place.

What Really Changed, and Why It Matters

As of June 20, 2025, Amazon raised the maximum allowable carton length for FBA shipments from 25 inches to 36 inches. Width, height, and the 50-pound weight limit remain unchanged. If you’re wondering whether this move is a big deal, the answer is yes, but with caveats.

This change opens the door for smarter packaging strategies. Think: better product bundling, reduced outer box count, and possibly some cost savings on inbound shipping if you optimize correctly. But before you go redesigning every carton, hold up—this doesn’t necessarily extend to AWD (Amazon Warehousing and Distribution), where size restrictions still apply in most cases.

The AWD Confusion Factor

A lot of sellers on Amazon forums and LinkedIn have been asking: “Does this apply to AWD too?” The short answer is: no, not really. AWD still enforces its own packaging criteria, especially around conveyable cartons. One seller summed it up well: “FBA might let me go long now, but AWD’s still playing by the old rulebook.”

The takeaway? Don’t assume this is a one‐size‐fits‐all update. Multichannel sellers and anyone using AWD for upstream storage should keep using separate carton spec templates.

Why Amazon Made This Move Now

This isn’t random. 2025 has been packed with changes to FBA and AWD capacity policies, fees, and prep requirements. This latest shift comes after Amazon:

• Reduced peak storage limits to ~5 months of forecasted sales
• Rolled out smart storage rate tiers for AWD
• Cracked down on inventory performance metrics

In that context, the 36-inch change looks less like a gift and more like an efficiency nudge. Amazon wants you to ship smarter, not bigger. But if bigger helps you ship smarter, you now have the green light.

The Pros, and the Not-So-Obvious Cons

The Good:

The Gotchas:

Smart Questions to Ask Right Now

• Which of my ASINs can benefit from the 36-inch allowance?
• Are my 3PLs or prep centers even aware of the change?
• Do I need to maintain separate carton rules for FBA vs AWD?
• Is my packaging team trained to avoid dimensional-weight traps?

What Sellers Are Saying

One seller on the forums wrote, “It’s about time… my standard lamps have been costing me extra for repackaging for years.” Another added, “Unless AWD follows suit, this just adds another layer of complexity.”

We’re seeing the same split across LinkedIn: half of the brands are optimistic, the other half are cautious. Everyone wants more flexibility, but not at the cost of downstream penalties or confusion.

Cahoot’s Edge: No Length Caps, No Guesswork

Here’s where we come in. At Cahoot, we don’t impose arbitrary box-length limits. Whether you ship 12 inches or 42 inches, our peer-to-peer fulfillment network accommodates your carton, not the other way around.

And because we operate channel-agnostic, there’s no need to split inventory or set up redundant prep processes just to comply with Amazon’s shifting rules. When Amazon changes the rules, we don’t scramble. Our systems are already built for flexibility.

Final Thought

Amazon’s carton-length change is an opportunity, if you know how to use it. It’s not a magic solution, but for the right SKUs, it can open up serious efficiency. Just make sure your fulfillment strategy isn’t relying on assumptions. Because at Amazon, the rules always change.

Frequently Asked Questions

What’s the new FBA box length limit?

The new maximum is 36 inches in length. Weight (50 lbs max), width, and height restrictions remain the same.

Does this apply to Amazon AWD?

No. AWD still enforces a 25-inch limit for conveyable cartons. Check your spec sheets before making changes.

Will this reduce shipping costs?

It can, especially if you bundle multiple units in one carton. But watch for dimensional weight traps.

Can Cahoot handle boxes over 36 inches?

Yes. Cahoot imposes no size limits on cartons, making it ideal for larger or irregularly shaped products.

Do I need to update my packaging workflows?

Probably. Most sellers will benefit from revisiting their pack plans and checking how their software handles the new dimensions.

• Category: Uncategorized
• Tag: Amazon, Cahoot, Shipping and Logistics