USPS, UPS and FedEx use other words for similar categories. USPS sorts parcels as machinable or nonstandard. UPS and FedEx charge an Additional Handling surcharge, and FedEx's rules include any package that "could become entangled in or cause damage to other packages or the FedEx sortation system." DHL Express does use the term in the US: it lists a Non-Conveyable Piece surcharge and says that name changes to Additional Handling from January 1, 2027.
What Makes an Item Non-Conveyable?
- Size. A side longer, wider or taller than the sorter takes.
- Weight. Too heavy for the belt.
- Shape. Round or cylindrical items such as mailing tubes, buckets, drums and pails roll; long or protruding items can jam.
- Packaging. Items not fully in a corrugated box, such as tires, items in shrink or stretch wrap, large poly bags, or parcels with loose banding or strapping.
- Too small or flat. Thin items can fail to scan or shift on the belt, and UPS routes packages 1 inch or less in height through its irregular package sortation process.
Examples include rugs and other rolled goods, furniture boxes, tires, pipes and coils of cable, gym equipment and anything shipped in a bucket or drum. Large goods like these are also called big and bulky items.
Carrier Rules and Surcharges
Fig. 1 · Comparison
| Item | Size and weight | Shape and packaging |
|---|---|---|
| USPS nonstandard parcel | Over 22 in long, 18 in wide, 15 in high or 25 lb | Tubes, rolls, cans, wood or metal boxes |
| UPS Additional Handling | Over 48 in long, 30 in second side, 105 in length plus girth or 50 lb | Not fully in corrugated, cylindrical, shrink or stretch wrapped, or 1 in high or less |
| FedEx Additional Handling | Over 48 in long, 30 in second side, 105 in length plus girth or 50 lb | Not fully encased, not corrugated, round, or could catch in the sorter |
Each carrier sets its own triggers and fees, and changes them. From the current guides:
- USPS. For USPS Ground Advantage Commercial, the October 4, 2026 price list adds $4.50 for a length over 22 inches up to 30 inches, $10.00 over 30 inches, and $21.00 over 2 cubic feet.
- UPS. The 2026 rate guide, effective September 7, 2026, lists Additional Handling in Zone 2 at $30.00 for length, $46.50 for weight and $26.75 for packaging, with a 40-pound minimum billable weight on the dimension charges. Above 130 inches in length plus girth, 96 inches long, 110 pounds or 17,280 cubic inches, the Large Package Surcharge applies instead.
- FedEx. FedEx lists its 2026 Additional Handling Surcharge in Zone 2 at $29.50 for dimensions, $46 for weight and $26.50 for packaging, with a 40-pound minimum billable weight on the dimension charge; its published 2027 changes take effect January 4, 2027.
Measure an irregular item the way UPS describes: as if it were in a rectangular box, from its extreme points. Size also drives dimensional weight pricing, which is separate from these surcharges. Freight past a carrier's parcel limits can move as LTL shipping instead.
Non-Conveyable Items in a Warehouse
A fulfillment center's own conveyors and sorters have limits too. Items outside them are stored, picked and packed on a separate path: floor or pallet rack storage instead of shelving, pallet jacks or forklifts instead of conveyors, and packing stations with room for large cartons. That separate path takes more labor and space per order, so a 3PL may price oversized items separately. See MHE (material handling equipment) for the equipment involved.
How to Reduce Non-Conveyable Charges
- Box it. Ship tubes, buckets and loose items inside a corrugated carton so the package is not cylindrical or unboxed.
- Right-size the carton. Keep the longest and second-longest sides under the carrier's triggers where the product allows.
- Know each carrier's limits. The same box can be standard for one carrier and nonstandard for another.
- Use a 3PL set up for it. A 3PL with big and bulky fulfillment has the space, equipment and carrier mix for these items.