How to Split a Product into Multiple Packages
Optimize Package Splitting to Meet Carrier Weight Limits and Avoid Errors
Overview
When packing orders, ShipperHQ gives you control over how products are split across boxes. Each carrier can enforce minimum and maximum package weights and maximum shipment weight limits.
Two settings affect the packing behavior:
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Don’t Show Carrier When Product Weight > Max Package Weight
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Allow Products to be Split Across Boxes During Packing
This guide explains how those two settings interact and what outcomes to expect at checkout.
Table
The following table explores different scenarios and outcomes based on the combinations of the two key settings. The table assumes a maximum package weight of 50 lbs, with Product 1 weighing 70 lbs and Product 2 weighing 30 lbs.
| Product 1: Carrier is hidden (and an error is shown) because its weight exceeds the 50 lb max and cannot be split. 2x Product 2: ShipperHQ splits into one 50 lb box and one 10 lb box. Splitting occurs only when products are individually under the max weight. |
| Product 1: Carrier is hidden (error shown) because the product exceeds the max weight. 2x Product 2: Each unit is packed in its own box (30 lbs each), since splitting is disabled. |
| Product 1: ShipperHQ splits into two boxes (50 lbs and 20 lbs), even though it exceeds the limit. 2x Product 2: Shipment is split into one 50 lb box and one 10 lb box. |
| Product 1: Carrier is hidden (error shown) because splitting is not allowed and the item exceeds the limit. 2x Product 2: Each unit is packed separately (30 lbs per box). |
IMPORTANT: If you're using a "Pack into Multiple Fixed Boxes" dimensional rule, ShipperHQ evaluates boxed weight, not just product weight. When “Split Across Boxes” is disabled, ShipperHQ may still show rates as long as the total boxed weight does not exceed the carrier’s limits. Always ensure your defined boxes stay within carrier weight limits to avoid rate errors. 💡