Case Study – Leicester to Japan

Quick Summary

A UK-based customer needed to ship a water-based solvent from Leicester, UK to Yokohama, Japan by air freight. Although the product was non-hazardous, the consignment initially failed airline X-ray security screening because it was packed in metal drums, making it difficult for security operators to scan the contents properly.

Following Pallet2Ship’s guidance, the goods were returned to the collection point, repacked into plastic containers, and subsequently passed security screening and were uplifted successfully. The shipment was booked in November, and this case highlights an important air freight lesson: packaging transparency is as critical as correct product declaration for UK to Japan air freight.

What Happened

In November, the customer booked an air freight shipment through Pallet2Ship to send a palletised consignment of water-based solvent from Leicester, UK to Yokohama, Japan.

The goods were correctly declared and securely packed in sealed metal drums. All standard export documentation was submitted, and the shipment was collected as planned.

However, during airline security screening, the shipment did not pass the initial X-ray scan. Due to the density and opacity of the metal drums, the security operator was unable to clearly see the contents, and the airline rejected the shipment for uplift.

The goods were returned to the original collection point in Leicester.

Pallet2Ship reviewed the carrier’s feedback with the customer and explained that:

• The issue was not related to the nature of the product


• The failure was caused by the packaging material, as metal drums prevented sufficient X-ray visibility


• Photos of the goods alone cannot confirm whether a shipment will pass X-ray screening

The customer then repacked the solvent into plastic containers, after which the shipment was rebooked and successfully cleared security.

What They Did Right - Booking & Documentation

• Declared the goods accurately as a water-based solvent, avoiding misclassification


• Entered correct weights, dimensions, and pallet details at the quote stage


• Selected air freight based on urgency and destination requirements


• Submitted all commercial invoice documentation promptly after booking


• Provided clear photos of the goods and packaging to support pre-booking checks

What They Did Right - Physical Preparation

• Ensured the solvent was sealed, stable, and leak-proof for transport


• After the failed scan, repacked the goods into plastic containers, improving X-ray transparency


• Secured the containers properly on the pallet to prevent movement or leakage


• Made the goods available again promptly at the collection point in Leicester


• Reattached all required documents in clear wallets to the pallet

Response & Resolution

• Acted quickly once advised of the screening issue


• Agreed to repackage the goods without delay


• Understood that photos and declarations alone cannot guarantee airline acceptance

What to Do vs What Not to Do

Do This

• Declare liquids accurately, even if non-hazardous


• Use plastic or transparent containers for air freight liquids where possible


• Respond quickly if advised to repackage after failed screening


• Keep goods accessible at the collection point for at least 48 hours in case of security screening issues


• Check air freight packaging requirements before booking when shipping liquids

Avoid This

• Using metal drums for liquid air freight due to poor X-ray visibility


• Assuming photos or product declarations guarantee security clearance


• Rebooking without addressing the underlying packaging issue


• Treating a failed scan as a documentation problem rather than a packaging issue

Why It Matters

For UK to Japan air freight, packaging transparency is just as important as correct documentation. Metal containers can trigger airline security rejections even when goods are non-hazardous and accurately declared.

X-ray screening standards vary by airline and route. What passes on European lanes may fail on long-haul Asia-Pacific routes to Japan due to stricter security protocols at airports such as Narita and Haneda.

In this case, Pallet2Ship’s guidance allowed the issue to be resolved quickly. The customer repacked the goods within 24 hours, the shipment was rebooked without misclassification or penalties, and the pallet was uplifted successfully for delivery to Yokohama.

For liquid shipments by air, understanding packaging requirements early can prevent avoidable delays. Where air freight is not suitable due to packaging or compliance constraints, alternative sea freight options may also be considered.