Ceramic and glass blanks are heavy, hard and brittle, which is exactly the wrong combination for a parcel network built around conveyor belts, chutes and stacked trucks. Double boxing is the simplest, most reliable way to get them through. Photo USA double boxes every fragile product at no extra charge, and this guide explains what that means, why it works, and how to double box the finished pieces you ship to your own customers.
Short answer: Double boxing, also called the box-in-box method, means packing fragile items in an inner box, then placing that box inside a larger outer carton with cushioning on every side. The outer box takes the impact and the cushioning gap absorbs it before it reaches the product.
A single box passes a drop straight to whatever is inside. With two boxes, a drop has to crush the outer wall, compress the cushioning and only then reach the inner box, which is still holding its contents in place. That is why carriers recommend the method for anything breakable.
Short answer: Yes. Every fragile product Photo USA ships is double boxed at no extra charge. Cases of ceramic, glass and other breakable blanks go inside a second outer carton with cushioning between the two walls.
Our shipping policy calls the outer carton the single biggest factor in whether a case survives the trip, and we treat it that way: it is not an upgrade you have to select or pay for. Orders ship from Fremont, CA or Shepherdsville, KY, whichever reaches you faster, and most leave within 24 hours of payment clearing. If a piece still arrives broken, see our guide to preventing breakage and filing a damage claim.
| What we ship | How it is packed |
|---|---|
| Ceramic mugs, steins and latte mugs | Double boxed, case inside an outer carton with cushioning |
| Glass mugs, shot glasses and pint glasses | Double boxed |
| Ceramic ornaments, tiles and plates | Double boxed |
| Photo slates and other breakable blanks | Double boxed |
| Stainless tumblers, puzzles, fabric and metal | Packed to suit the product |
Short answer: Wrap each piece, pack it snugly in an inner box, then place that box in an outer carton about 6 inches larger in length, width and depth, with about 3 inches of cushioning around the inner box on every side. Seal the outer box with shipping tape.
That spacing follows the box-in-box method in the UPS packaging guidelines. Step by step for a finished mug:
Short answer: Double box anything that can crack or shatter: ceramic, glass, porcelain, stoneware and slate. Stainless steel tumblers, puzzles, mouse pads, fabric and metal panels usually travel fine in one well packed box.
| Product | Double box? | Why |
|---|---|---|
| Ceramic and bone china mugs | Yes | Handles and rims chip or snap on a drop |
| Glass mugs, shot glasses, pint glasses | Yes | Glass shatters rather than chips |
| Ceramic plates, tiles and ornaments | Yes | Flat ceramics crack under pressure from stacking |
| Photo slates | Yes | Slate edges chip and corners break |
| Stainless steel tumblers | Usually not | They dent rather than break; protect the print from scuffs |
| Puzzles, mouse pads, fabric, metal panels | No | Not breakable; one box keeps them flat and clean |
Want your ceramic blanks to arrive in one piece? Photo USA sells by the case with a one case minimum and no minimum number of cases, and most orders ship within 24 hours from Fremont, CA and Shepherdsville, KY. We also offer a wholesale imprint service if you would rather receive finished pieces. Email hello@photomugs.com or contact us with the items and quantities you need.
Short answer: For ceramic and glass, almost always. An outer carton and some cushioning cost far less than one remade mug, a second shipping label and a customer who has to wait twice.
A broken personalized mug cannot be replaced from stock. You have to re-press it, repack it and pay to ship it again, and the customer who was buying a gift for a date may not get it in time. For one off orders, a mug-sized gift box inside a slightly larger mailer with cushioning is the simplest way to double box without slowing down your packing table. The Photo USA 11 oz gift box measures 4 x 4 x 4 inches and is $57.60 for a case of 144.
Short answer: One line on your product page or order confirmation is enough: say that fragile items are double boxed, and ask customers to keep the packaging and send photos if anything arrives damaged.
Here is wording you can copy: "Every mug is double boxed for safe delivery. If anything arrives damaged, please keep the box and send us photos of the item and the packaging within a few days, and we will make it right." It sets expectations, reduces anxiety for gift buyers, and gives you the photos you need if you have to file a claim with the carrier.
Double boxed means the product is packed in an inner box, which is then placed inside a larger outer carton with cushioning between the two. The outer box and cushioning absorb drops and pressure before they reach the product.
Yes. Photo USA double boxes every fragile product at no extra charge. Cases of ceramic, glass and other breakable blanks go inside a second outer carton with cushioning between the two walls.
No. Double boxing is included on all fragile products. Shipping is calculated at checkout based on weight, case count and destination ZIP code.
The UPS box-in-box method recommends an outer box about 6 inches larger than the inner box in length, width and depth, with about 3 inches of cushioning around the inner box on every side.
Fill the inside of the mug with paper, wrap the handle with an extra layer of bubble wrap, wrap the whole mug in several layers, pack it snugly in an inner box such as a mug gift box, and place that box in a larger outer carton with cushioning on all sides.
Ceramic and bone china mugs, glass mugs and shot glasses, ceramic plates, tiles and ornaments, and photo slates. Stainless steel tumblers, puzzles, mouse pads and fabric usually travel fine in one well packed box.
Keep the box and packing, take photos of the damaged items and the outer carton, and contact the seller. For Photo USA orders, report it within 5 business days of delivery with photos, and we will replace or refund the damaged items and cover the shipping.
Yes. The Photo USA 11 oz mug gift box measures 4 x 4 x 4 inches and is $57.60 for a case of 144. It works as the inner box when you double box a finished mug.
One last note: the box-in-box spacing in this guide follows general carrier guidance. Heavier or oddly shaped items may need more cushioning, so check your carrier's own packaging rules for the service you use, and keep the box and photos for any shipment that arrives damaged.
