How to Pack Robot Mower for Shipping

I have worked with Ambrogio robot mower customers for 15 years. Our customers are located throughout the United States. Anyone's robot mower can require repair and every robot mower needs Winter Service. Often our customers save the original box with its original molded styrofoam. Customers who could not keep the original box will benefit from these packing instructions.

How to Pack Robot Mower for Shipping 

Look no further, this post will tell you best practices and a proven packing method that virtually guarantees shipping damage cannot occur.

If you find the process to pack robot mower for shipping intimidating, there is an easy solution, but it is not guaranteed to avoid shipping damage. Take the robot to a UPS Store or Fedex Office location and pay them to pack it. Inquire about insurance and guarantees for the packing services. Often a mishap will be covered, but that does not eliminate the possibility of an inconvenience or a delay in your robot's return. The best way to avoid problems is to follow these instructions. Since almost every retail outlet's workers would not be an expert at packing a heavy irregular item like a robot mower, they can learn how to pack robot mower for shipping by reading this post. Send them a link and ask them to read it - it can't hurt!

General Robot Mower Packing Rules

Use the Correct Size and Type of Box

1. Measure the robot mower or look up its dimensions. Now add 4"/10cm to each dimension. Find a box that is at least these padded dimensions, or larger.
2. Weigh the robot mower, or look up its weight. If the robot mower weighs 25lbs or more, use a heavy-duty double-walled box. 
3. If the robot mower weighs less than 25lbs, a standard box is acceptable, provided it is in good condition or is reinforced with packing tape on all seams. Run strapping tape around its girth to ensure the box does not burst when dropped.

Use the Right Packing Materials

1. Always use large size heavy-duty bubble wrap (3/4-1" bubbles) to pack robot mower for shipping
2. Sturdy styrofoam blocks and/or peanuts are best. Cornstarch/soft peanuts are not acceptable because they will be crushed by the weight of the robot.
3. Crushed paper is unsuitable. The robot mower's weight will flatten it.

Consider the Laws of Physics

1. When you pack your robot mower for shipping, think about the laws of physics. Consider that the box will be thrown by handlers and may land on a hard surface in every direction.
2. Air is the best cushion. Consider that the robot's wheels should be suspended within the box over a layer of air to prevent a concussion-induced failure mode. Create air cushions with sturdy cardboard, multiple layers of bubble wrap, styrofoam blocks and multiple layers of packing peanuts.
3. Ensure the robot mower cannot move around inside the box, which protects it from a "concussion" inside the box.
4. Do not leave empty space inside the box that can cause the box to deform after an outside impact.

How to Pack Robot Mower for Shipping Example

This example uses a very large, heavy robot mower since larger/heavier robots are more difficult to pack and are more likely to experience shipping damage. The purpose of the packing method is to ensure shipping damage does not occur even if the package is dropped 3 feet or more.

Step 1: Protect the Robot Mower: Make a "Cocoon"

Ambrogio Robot Mower Being Wrapped for Shipping

Creating a cocoon around the robot will protect it from impact in all directions. Heavy robots will benefit from some additional cushioning around the wheels. In this example, spongy styrofoam was used to reduce the impact of shocks such as when the box is dropped upright.

Ambrogio Robot Mower Underside with Extra Styrofoam

Another key aspect of creating the cocoon is to use multiple layers of bubble wrap. Use strong packing tape across adjoining layers to pull the bubble wrap tightly to the body of the robot. It is not necessary to tape the bubble wrap to the robot. Placing the tape around each bubble wrap layer is sufficient. A loose bubble wrap cocoon will be ineffective at protecting the robot.

Check each edge of the robot by touching it with your hand. You should feel air, not the robot mower. If you feel the robot mower, tape another layer of bubble wrap over the weak spot. This is what the finished cocoon will look like:

Ambrogio Robot Mower after being "Cocooned" for Shipping

Step 2: Prepare the Box Bottom

There are two options for preparing the bottom of the box: 1) Use heavy duty cardboard to create an air-gap layer (pictured)  2) Put 2-3" of sturdy packing peanuts in the box bottom. Shake to distribute evenly, add more if needed. The box bottom must not be visible through the peanuts.

Cardboard Air Gap Cushions Robot Wheels Further

Step 3: Place the Cocoon in the Prepared Box

Add the cocoon as shown. A properly chosen box will have space remaining for more packing material around the cocoon. Insert bubble wrap and or styrofoam to brace the cocoon in the center of the box, i.e. to guarantee the cocoon cannot move around inside the box when it is thrown in any direction.

Ambrogio Robot Cocoon in Box Before and After Bracing

Step 4: Fill all Voids

Almost finished! How to pack robot mower for shipping properly requires filling all voids. A "void" is a packing term that means "air space". When you fill voids, you are eliminating all of the air space. This is important because it keeps the box from becoming deformed due to an impact. Filling voids helps the box maintain its structural integrity. Rolled-up bubble wrap and sturdy packing peanuts are the best materials for filling a packed robot's voids. When using packing peanuts, shake them down or press on them to ensure their effectiveness won't change due to settling in transit.

Ambrogio Robot Mower, Packed

Step 5: Cover the Top

Remember that protecting the top of the cocoon is just as important as protecting its bottom. Fill the box with packing peanuts but don't add so many that the box top cannot be closed tightly. The volume of peanuts is right when it takes effort to squeeze the flaps together, but not so much effort that the flaps deform. The photo in Step 4 shows an appropriate amount of peanuts on top of the cocoon.

Step 6: Seal the Box

Adhering multiple layers of packing tape on all seams is the best way to seal the box, ensuring the flaps are brought together tightly, without bulging. Adding tape around the girth can be a good idea as well. Also add tape to reinforce glued box seams, as in the picture below.

Glued Box Seam, Add Tape to this Seam

Packing a robot mower for shipping is nothing to fear. Follow the six steps in this post and your robot will arrive at its destination safely. 

How to Pack a Robot Mower Video

Here is a video that shows the creation of the robot's cocoon in action:

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