Best Carrier for Heavy Products on Shopify (2025 Comparison)
For most heavy products (20-70 lbs), UPS Ground offers the best combination of pricing, reliability, and handling for Shopify stores. FedEx Ground is competitive and sometimes cheaper for specific routes. USPS is not viable for products over 70 lbs and becomes expensive above 20 lbs. For very heavy items (100+ lbs), freight carriers (LTL) become cost-effective. Negotiated rates are essential—list prices for heavy products can be 30-50% higher than what you should pay at moderate volume.
Shipping a 5 lb package? Any carrier works. Shipping 30, 50, or 100 lbs? Now carrier choice matters enormously. The rate differences between carriers for heavy products can exceed 40%—and choosing wrong costs thousands monthly.
Heavy products present unique shipping challenges: weight-based pricing accelerates costs, handling requirements increase damage risk, and residential delivery surcharges pile on. This guide compares carriers specifically for heavy product shipping and helps you choose the right one for your Shopify store.
Why Heavy Products Are Different
Weight-Based Pricing Accelerates
Shipping costs don't scale linearly with weight—they accelerate:
| Weight | UPS Ground Zone 5 | Cost per lb |
|---|---|---|
| 5 lbs | $12.50 | $2.50 |
| 10 lbs | $16.80 | $1.68 |
| 20 lbs | $24.50 | $1.23 |
| 30 lbs | $32.40 | $1.08 |
| 50 lbs | $48.90 | $0.98 |
| 70 lbs | $68.50 | $0.98 |
Cost per pound decreases—but total cost still climbs fast.
DIM Weight Usually Doesn't Apply
For heavy products, actual weight typically exceeds DIM weight:
| Product | Dimensions | DIM Weight | Actual Weight | Billable |
|---|---|---|---|---|
| Dumbbells | 12×8×8 | 5.5 lbs | 35 lbs | 35 lbs |
| Furniture | 24×20×12 | 41 lbs | 45 lbs | 45 lbs |
| Equipment | 18×14×12 | 22 lbs | 50 lbs | 50 lbs |
Heavy products ship at actual weight—packaging optimization has limited impact.
Handling Risk Increases
Heavy packages face more handling challenges:
| Factor | Impact |
|---|---|
| More likely to be dropped | Weight makes handling harder |
| Belt conveyor limits | Heavy items often hand-carried |
| Stacking damage | Weight crushes lighter packages |
| Driver handling | Residential delivery = one person |
Damage rates for heavy products run 2-3× light package rates.
Carrier Comparison: Heavy Products
UPS Ground
The default choice for heavy products.
| Weight Range | Strength |
|---|---|
| 20-50 lbs | Strong, competitive |
| 50-70 lbs | Strong, competitive |
| 70-150 lbs | Available (UPS Over 70 program) |
Pricing (Zone 5, 2025 list rates):
| Weight | List Rate | Typical Negotiated |
|---|---|---|
| 30 lbs | $38.50 | $28-32 |
| 50 lbs | $58.90 | $42-48 |
| 70 lbs | $82.50 | $58-65 |
Pros:
- Reliable handling processes for heavy items
- Over 70 lb program for very heavy products
- Strong tracking and claims process
- Good volume discount potential
Cons:
- List rates are high
- Residential surcharges add up
- Additional handling fees for large packages
Best for: 20-70 lb products shipping nationally, B2B shipments
USPS (Priority Mail / Ground Advantage)
Limited viability for heavy products.
| Weight Range | Viability |
|---|---|
| 15-25 lbs | Marginal |
| 25-50 lbs | Generally not competitive |
| 50-70 lbs | Usually more expensive |
| 70+ lbs | **Not available** (70 lb limit) |
Pricing (Zone 5, 2025):
| Weight | Priority Mail |
|---|---|
| 20 lbs | $32.50 |
| 30 lbs | $45.80 |
| 50 lbs | $68.90 |
| 70 lbs | $95.50 |
Pros:
- Sometimes competitive for 15-25 lb range
- No residential surcharges
- Saturday delivery included
- Good rural delivery
Cons:
- 70 lb maximum weight limit
- Expensive above 25 lbs
- Less reliable handling for heavy items
- Limited tracking detail
Best for: 15-25 lb products to rural/residential addresses
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Regional Carriers
Viable for specific geographies.
| Carrier | Coverage | Heavy Product Capability |
|---|---|---|
| OnTrac | West Coast | Up to 70 lbs |
| LSO | Texas/Midwest | Up to 70 lbs |
| Spee-Dee | Upper Midwest | Up to 70 lbs |
When regional carriers win:
- 40%+ of shipments to their coverage area
- 20-50 lb products (sweet spot)
- Cost savings of 15-25% vs national carriers
Limitations:
- Geographic restrictions
- Less robust handling for heavy items
- Integration complexity
---
Freight (LTL) Carriers
For very heavy and bulky items.
| Weight Range | Recommendation |
|---|---|
| 70-150 lbs | Consider freight quotes |
| 150-500 lbs | Freight usually wins |
| 500+ lbs | Freight is only option |
Major LTL carriers:
- FedEx Freight
- UPS Freight
- XPO Logistics
- Estes Express
- Old Dominion
Pricing structure:
- Class-based (density determines class)
- Weight breaks (100, 500, 1000 lbs)
- Accessorials (liftgate, residential, notify)
Example: 200 lb shipment, Zone 5
| Method | Estimated Cost |
|---|---|
| UPS Ground (not available >150 lbs) | N/A |
| FedEx Freight | $85-120 |
| LTL (negotiated) | $65-95 |
Best for: Furniture, equipment, palletized goods, 150+ lbs
Weight Thresholds to Know
Carrier Weight Limits
| Carrier | Maximum Weight |
|---|---|
| USPS | 70 lbs |
| UPS Ground (standard) | 70 lbs |
| UPS Ground (Over 70) | 150 lbs |
| FedEx Ground | 70 lbs |
| FedEx Oversize | 150 lbs |
| Freight (LTL) | No practical limit |
Pricing Break Points
| Weight | Pricing Note |
|---|---|
| 1 lb | Minimum charge typically applies |
| 5 lbs | Light package rates end |
| 10 lbs | Mid-range pricing begins |
| 20 lbs | Heavy package pricing accelerates |
| 50 lbs | Premium heavy pricing |
| 70 lbs | Standard carrier limit |
| 150 lbs | Max for parcel; consider freight |
Surcharge Triggers
| Trigger | UPS | FedEx |
|---|---|---|
| Over 50 lbs | $18-22 | $16-20 |
| Over 70 lbs | $85-95 | $80-90 |
| Over 48" length | $18-22 | $16-20 |
| Residential delivery | $4.50-5.50 | $4.25-5.25 |
Choosing the Right Carrier
Decision Framework
Step 1: Determine weight category
| Category | Primary Consideration |
|---|---|
| 15-30 lbs | Compare all three (UPS, FedEx, USPS) |
| 30-70 lbs | UPS vs FedEx (USPS rarely competitive) |
| 70-150 lbs | UPS/FedEx Over 70 vs freight quotes |
| 150+ lbs | Freight (LTL) |
Step 2: Evaluate destination mix
| Destination Type | Carrier Advantage |
|---|---|
| Primarily business | UPS/FedEx (no resi surcharge) |
| Primarily residential | Compare resi rates carefully |
| Rural heavy | USPS may have advantages |
| Regional concentration | Regional carriers may win |
Step 3: Consider volume
| Monthly Volume | Approach |
|---|---|
| <100 heavy packages | Use aggregators, compare rates |
| 100-500 | Negotiate directly with 2-3 carriers |
| 500+ | Dedicated account management |
Rate Comparison Example
30 lb package, residential Zone 5:
| Carrier | List Rate | With Surcharges | Negotiated |
|---|---|---|---|
| UPS Ground | $38.50 | $44.00 | $32-35 |
| FedEx Ground | $37.80 | $43.00 | $31-34 |
| USPS Priority | $45.80 | $45.80 | $42-44 |
Winner: FedEx or UPS with negotiated rates
50 lb package, business Zone 4:
| Carrier | List Rate | Negotiated |
|---|---|---|
| UPS Ground | $52.50 | $38-42 |
| FedEx Ground | $51.20 | $37-41 |
| USPS Priority | $58.90 | $54-56 |
Winner: FedEx or UPS (USPS not competitive)
Surcharges That Matter for Heavy Products
Additional Handling Charges
Triggered by heavy weight:
| Trigger | UPS | FedEx |
|---|---|---|
| Over 50 lbs | $18.00 | $16.50 |
| Over 70 lbs | $95.00 | $90.00 |
| Longest side >48" | $18.00 | $16.50 |
| Second longest >30" | $18.00 | $16.50 |
Residential Surcharges
| Carrier | Ground Residential | Home Delivery |
|---|---|---|
| UPS | $5.30 | N/A |
| FedEx | $5.10 | $5.40 |
Over-Max Surcharges
| Carrier | Over 150 lbs | Over 108" length |
|---|---|---|
| UPS | Not accepted | Not accepted |
| FedEx | Not accepted | Not accepted |
| Freight | Standard | Standard |
Negotiation Strategies for Heavy Products
When to Negotiate
| Signal | Action |
|---|---|
| 50+ heavy packages/month | Negotiate with carriers |
| 20%+ of shipments are heavy | Include in rate negotiations |
| Consistent weight profile | Leverage predictability |
What to Negotiate
| Item | Negotiation Potential |
|---|---|
| Base rates | 15-30% off list |
| Additional handling charges | 25-50% discount |
| Residential surcharges | 10-20% discount |
| Peak season surcharges | 50% discount possible |
Negotiation Script
"We ship [X] heavy packages monthly averaging [Y] lbs. Our current carrier is [Z]. We're evaluating options and want to understand your best pricing for this profile."
Key leverage:
- Multi-carrier quotes
- Volume commitment
- Consistent weight profile
- Year-over-year growth potential
Heavy Product Best Practices
Packaging for Heavy Items
| Practice | Benefit |
|---|---|
| Double-wall corrugated | Prevents crushing |
| Corner protectors | Handles impact |
| Strapping/banding | Keeps contents secure |
| "Team Lift" labels | Alerts handlers |
| Multiple handles | Easier handling |
Insurance Considerations
Heavy products often = higher value = insurance needed:
| Coverage | UPS | FedEx |
|---|---|---|
| Included | $100 | $100 |
| Additional (per $100) | $0.90-1.10 | $0.85-1.05 |
| Third-party options | $0.45-0.65 | $0.45-0.65 |
Damage Prevention
| Strategy | Implementation |
|---|---|
| Overpacking | 15-20% extra cushioning |
| Shock/tilt indicators | Visual damage evidence |
| Photos at packing | Documentation for claims |
| Signature required | Accountability |
Frequently Asked Questions
What's the cheapest way to ship heavy products?
UPS or FedEx Ground with negotiated rates typically wins for 20-70 lb products. For 150+ lbs, freight (LTL) becomes cost-effective. Always compare—there's no universal "cheapest" without knowing weight, dimensions, origin, and destination.
Can I ship 100 lb packages via UPS or FedEx?
Yes, both have Over 70 programs allowing packages up to 150 lbs. However, surcharges are significant ($85-95), and freight quotes may be competitive at this weight.
Why is USPS so expensive for heavy products?
USPS pricing structure is optimized for light packages. Their per-pound cost above 20 lbs climbs faster than UPS/FedEx. Additionally, USPS has a hard 70 lb limit.
When should I switch to freight shipping?
Consider freight when: (1) packages exceed 100 lbs, (2) packages exceed 108" in any dimension, (3) you're shipping palletized goods, or (4) ground rates with surcharges exceed freight quotes.
How much can I save by negotiating heavy product rates?
Expect 15-30% off list rates at 100+ packages/month. Additional handling surcharges are particularly negotiable—50% discounts are possible. Total savings of 20-35% are achievable.
Should I use different carriers for heavy vs light products?
Often yes. Many stores use USPS for light products (<5 lbs) and UPS/FedEx for heavy products. Multi-carrier strategies optimize cost but add complexity.
Sources & References
- [1]UPS Shipping Rates - UPS (2025)
- [2]FedEx Ground Rates - FedEx (2025)
- [3]USPS Weight Limits - USPS (2025)
- [4]Freight Shipping Guide - FreightQuote (2024)
Attribute Team
The Attribute team combines decades of e-commerce experience, having helped scale stores to $20M+ in revenue. We build the Shopify apps we wish we had as merchants.