Complete FBA Prep Guide: Labeling, Packaging & Compliance A U.S.-First Playbook That Also Works for Cross-Border Sellers Shipping into Amazon FBA (Updated Dec 2025)

TL;DR

FBA prep is the labeling, packaging, and compliance work required so Amazon can receive, store, pick, and ship your inventory without manual intervention. Most inbound failures come from barcode conflicts, missing carton/pallet identifiers, and packaging that opens, leaks, breaks, or separates in warehouse handling. Starting January 1, 2026, Amazon states it will no longer offer prep and item labeling services for U.S. FBA shipments—so every unit must arrive fully prepped and fully labeled before it reaches an Amazon facility. Official notice.

This guide is written for Amazon US sellers first, because the U.S. inbound network sets the baseline expectations for scan-ability and packaging integrity. But it is designed to remain useful if you sell globally and ship into EU/UK/CA/JP marketplaces—especially if you manufacture in China and route inventory cross-border before it reaches FBA.

If you want a production workflow (barcode control, packaging QA, carton discipline, cross-border readiness), Get Started for Free.

FAST ANSWERS : WHAT ACTUALLY CAUSES AMAZON INBOUND FAILURES?

CRITICAL UPDATE: AMAZON ENDING U.S. FBA PREP SERVICES IN 2026

Amazon’s official FBA Prep Service page includes this note: starting January 1, 2026, it will no longer offer prep and item labeling services for FBA shipments in the U.S. store. Official policy page.

What this means operationally (U.S.-first, global impact):

• If you relied on Amazon for labeling, bagging, bubble wrap, or bundling, that safety net is gone for U.S. inbound.
• All units must arrive “scan-ready” and “damage-ready” before they reach an Amazon facility.
• Cross-border sellers must shift prep upstream: factory, origin warehouse, or a fulfillment partner.

HOW AMAZON RECEIVING “DECIDES” IF INVENTORY IS ACCEPTABLE

The best way to think about FBA prep is not “Did we follow a checklist?” It is “Will Amazon’s system accept this inventory without intervention?”

Amazon receiving outcomes are driven by two root causes:

• Identity failures (scan problems): barcode conflicts, unreadable labels, missing carton/pallet identifiers
• Integrity failures (handling problems): packaging opens/leaks/breaks, sets separate, sharp items puncture, liquids leak

Ready rule of thumb:
After prep, each unit should have one scannable identity and packaging that remains intact through warehouse handling.

UNDERSTANDING FBA PREP CATEGORIES

Amazon prep categories are less about product “type” and more about how products behave in storage and picking. If you classify based on marketing categories, you miss the real risk profile.

Amazon’s packaging guidance is the baseline reference for packaging and bagging expectations. Product packaging requirements.

FBA LABELING REQUIREMENTS (UNIT, CARTON, PALLET)

Most expensive labeling mistake:
Leaving multiple scannable barcodes visible after applying an FNSKU or other label. If a scanner reads the wrong code, receiving results become unpredictable.

1) Unit labeling: FNSKU vs manufacturer barcode

Most U.S. sellers choose FNSKU to control unit identity. The practical goal is not “use FNSKU,” it is one scannable identity per unit. If any other barcode remains scannable, you have created a receiving failure condition.

• Place unit labels on flat, visible surfaces
• Do not wrap labels around curves or edges
• Fully cover or render other barcodes unscannable
• Run a quick scan test before cartons are sealed

2) Carton labeling: FBA Box ID labels

Each box must have its own FBA Box ID label printed from the shipment workflow. Label placement matters: put it on a flat surface next to the carrier label so barcodes do not fold over edges. Shipping label requirements.

3) Pallet labeling: LTL / FTL shipments

If you ship pallets (common for U.S. inbound at scale), each pallet requires four Pallet ID labels (one on each side), and each box on the pallet still needs its own Box ID label. Shipping & routing requirements.

4) Bagging warnings and mandatory labels

Poly bags with a 5-inch opening or larger (measured when flat) must have a suffocation warning printed or attached as a label. Bagging requirements.

FBA PACKAGING GUIDELINES (WHAT PREVENTS REJECTION)

U.S. sellers often confuse “retail-ready” packaging with “FBA-ready” packaging. Amazon’s warehouse environment is repetitive: pick faces, bins, conveyance, packing stations, and returns handling. Packaging needs to survive the boring, unglamorous reality of warehouse touches.

General packaging principles (applies globally):

• Fully enclosed packaging for units that could be exposed to dust, friction, or compression
• Seals that hold under handling (bags, caps, tape, adhesive strips)
• Protection for fragile surfaces (secondary packaging where required)
• Prevent separation for sets and multi-part products

Poly bags: what sellers miss

• Ensure barcode/ASIN label remains visible through a clear bag or is printed on the outside
• Use a secure seal so the bag does not open in handling
• Add required suffocation warnings when applicable

Fragile items: “warehouse-safe” thinking

A fragile item that survived ocean freight can still fail at Amazon because it experiences repeated short drops, compression, and surface impacts across picking and packing. The goal is to prevent micro-damage that becomes customer returns.

Liquids and powders

Leakage is a fast path to refusal. Use closure discipline (cap seals), secondary containment when necessary, and packaging that remains intact under compression.

Sharp items

If a sharp edge or point can reach outer packaging, it becomes a puncture risk. The practical standard is: no edge should be able to cut or pierce the outer package during handling.

COMPLIANCE & RESTRICTED PRODUCTS (HAZMAT, EXPIRATION, PROHIBITED)

Clarification:
Amazon’s internal classification determines whether an item is treated as dangerous goods (hazmat) for FBA. Sellers are responsible for accurate documentation, data, and program compliance.

Dangerous goods (Hazmat) overview

The practical failure mode is not “hazmat exists.” It is shipping inventory that Amazon considers restricted without completing eligibility, documentation, and packaging requirements. If an item is flagged, inventory can be blocked or inbound can be disrupted.

Prohibited or restricted products

Many products become restricted not because they are illegal, but because they create handling, safety, or compliance risk at scale (batteries, chemicals, aerosols, magnets, and certain medical or regulated items). Validate eligibility before you build large inbound shipments.

Expiration-dated inventory

Expiration labeling must remain visible after prep. If you label over an expiration date, you have created a compliance failure even if the unit was otherwise “correct.”

INTERNATIONAL & CROSS-BORDER FBA PREP CONSIDERATIONS

U.S. inbound rules are the baseline. Cross-border sellers then inherit additional layers: customs, broker/clearance rules, and marketplace-specific requirements.

U.S.-first, global-ready checklist (what changes cross-border):

• Customs data discipline: consistent product descriptions, declared values, and HS codes across invoices and filings
• Country-of-origin markings: establish a consistent marking strategy when required
• Marketplace differences: EU/UK/CA/JP may impose different label language or compliance expectations
• Carrier handoff reality: cross-border introduces new failure points before inventory ever reaches Amazon

TOP FBA PREP MISTAKES (COSTS + FIXES)

TOOLS & WORKFLOWS (POST-2026 REALITY)

In 2026, FBA prep becomes an execution layer you control, not a service you request. The winning setup is not a tool list—it is a workflow that produces consistent results.

Workflow controls that consistently reduce inbound issues:

• One scannable identity rule per unit after prep
• Scan test before cartons are sealed
• Carton content discipline (no mixed surprises)
• Label placement discipline (flat surfaces, no edge folds)
• High-risk SKU QA for liquids, fragile items, sharp items, and sets

If you manufacture overseas, this is where fulfillment partners matter: the goal is not “cheap prep,” it is predictable receiving outcomes. Unlike traditional 3PLs that may emphasize storage and transportation, WinsBS operates as a fulfillment-first execution partner focused on order and inbound execution quality.

If you want a workflow fit check for your SKUs and inbound plan, Get Started for Free.

FINAL CHECKLIST BEFORE SHIPPING TO FBA

Copy/paste checklist:
Every unit has one scannable barcode, packaging stays intact in handling, carton and pallet IDs are correct and visible, and compliance eligibility is confirmed before shipment creation.

• Unit identity: Exactly one scannable barcode/label per unit after prep
• Label placement: Flat, visible, high-contrast; no curves/edges
• Bagging: Secure seal; warnings applied when required for 5” openings
• Sets: Physically bundled; marked “Sold as set / Do not separate”
• Fragile: Secondary protection applied where breakage risk exists
• Liquids: Leakage safeguards and containment as needed
• Sharp items: No edge can puncture outer packaging
• Cartons: Unique Box ID per carton; old labels removed/covered; labels on flat surfaces
• Pallets (if used): Stable load; four Pallet ID labels; cartons retain Box IDs
• Compliance: Restricted/hazmat status verified; expiration labels remain visible if applicable
• Post-2026 readiness: Do not rely on Amazon U.S. prep or labeling services

PEOPLE ALSO ASK: SHORT ANSWERS

FINAL RECOMMENDATION (U.S.-FIRST, GLOBAL-READY)

The decision question is no longer “Did we follow the rules?” It is: Will Amazon’s system accept this inventory without intervention? If you design prep around that question, you reduce delays, rework costs, and account health risk—whether you ship domestically in the U.S. or cross-border into multiple marketplaces.

If you want a prep-ready inbound workflow that is U.S.-first but works globally (barcode control, packaging QA, carton/pallet discipline, cross-border readiness), Get Started for Free.