How do I stop UPS weight and size adjustment charges on Etsy shipments?

Hi! If you’re measuring carefully and still getting UPS adjustments through ShipStation, it’s usually because UPS is rounding differently than you are (especially on dimensions) or because the box changes shape in transit (bulges/bows), so UPS’s automated scanners “see” a slightly bigger package than what you entered. The fastest way to reduce repeat adjustments is to standardize how you measure (and round) every box size, then build those exact presets into ShipStation so you’re not retyping anything.

Here are the best prevention steps that actually move the needle:

1) Round dimensions the way UPS’s scanners do (don’t use fractions).
Even tiny fractions can trigger a “dimension corrected” adjustment. Measure length x width x height at the widest points (including bulges, seams, extra tape, edge crush, handles, etc.), then round each dimension up to the next whole inch. If you’re currently entering 20.5" or 20.25", stop—use 21".
This is the #1 reason sellers feel like they “rounded up” but still get hit.

2) Prevent “box growth” in transit (this is more common than people think).
UPS measures what arrives on the conveyor—not what it looked like on your packing table. Common causes:

• Overstuffed cartons that bow out (especially on heavier items)
• Single-wall boxes for heavy shipments (sides bulge)
• Soft mailers or wrapped items that don’t hold a consistent shape
• Lots of tape creating ridges, or loose ends lifting

If you ship heavy/large items, upgrading to a stronger box (or a slightly larger box with better padding so it isn’t under pressure) can reduce adjustments even if it feels counterintuitive.

3) Lock your ShipStation package presets + automation (stop re-keying).
Create saved package types for your common cartons (Box A, Box B, etc.) with the rounded-up whole-inch dimensions and use them every time. Then add an automation rule so orders default to the right preset based on SKU, order weight range, or Etsy shipping profile. This prevents “one-off” entries that end up being the problem shipment.

4) Calibrate your scale and weigh like a carrier would.

• Confirm the scale is accurate (quick test with a known weight).
• Weigh the fully packed, taped box (not the item).
• If you’re near the next pound, round up (UPS billable weight rounds up, and dimensional weight can override scale weight).

5) Watch for “it’s not just weight/dims” adjustments.
Some UPS adjustments happen because of things like irregular packaging, oversize/large-package rules, address corrections, or selecting a package type that doesn’t match what you shipped. Make sure the ShipStation package type and service you select matches the real-world package (your own box vs carrier packaging, etc.).

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Disputing adjustments (what tends to work)

Because you’re buying UPS labels through ShipStation, ShipStation is usually the gatekeeper for disputes, and UPS decides the outcome—so the goal is to give ShipStation support something UPS will accept as “proof,” not just “I measured it.”

Do this for each disputed label:

• Tracking number + ship date
• What you entered in ShipStation (weight + L/W/H + package type)
• What UPS changed it to (the adjusted weight/dims and charge)
• Photo proof (this matters a lot):
  • Box on a scale showing the weight reading
  • Measuring tape on the box showing L/W/H (ideally 3 photos, one per dimension)
  • Photo showing the box is fully packed and sealed (so it matches what shipped)

Tips to increase your win rate:

• Dispute quickly (don’t wait—there’s typically a time limit from delivery).
• If it’s happening repeatedly on the same box size, dispute a few with very strong photos and at the same time change your presets to the next whole inch. Otherwise you’ll keep “winning” a few and losing many.
• If you drop off at a staffed counter, keeping a receipt can sometimes help, but photos of weight/dimensions are usually more persuasive than a basic drop-off scan.

One more thing: ShipStation can also add its own processing fee when a carrier applies an adjustment, so even if the carrier portion is small, the total sting can feel bigger—another reason it’s worth fixing the root cause (rounding + box deformation) rather than living in dispute mode.

If you tell me one example of a shipment that got adjusted (what you entered for L/W/H and weight vs what UPS changed it to), I can help you spot the pattern and tell you exactly what to change in your ShipStation box presets.