Travelling Light: How to Pack Efficiently and Avoid Excess Baggage Fees

Nothing puts a damper on holiday excitement quite like standing at the check-in counter watching your bags tip the scales into overweight territory. With Australian airlines increasingly strict about baggage limits and excess fees climbing year after year, mastering the art of efficient packing has become an essential travel skill. This guide will help you pack smarter, lighter, and with confidence—whether you're heading interstate for a weekend or embarking on an international adventure.

Understanding Australian Airline Baggage Policies

Before packing, know exactly what you're working with. Baggage allowances vary significantly between airlines and fare classes:

Domestic Flights

• Qantas: Economy typically allows 23kg checked plus 7kg carry-on
• Virgin Australia: Similar to Qantas at 23kg checked, 7kg carry-on for most fares
• Jetstar: Basic fares often include only 7kg carry-on; checked bags purchased separately
• Rex Airlines: Varies by route; some allow only 15kg checked

International Flights

International allowances depend on destination, airline, and fare class. Long-haul flights to the US or Europe typically allow more (often 30kg) than short-haul regional flights. Always verify your specific allowance before packing.

Strategic Clothing Selection

Clothing typically accounts for the majority of luggage weight. Smart choices here yield the biggest savings:

Build a Capsule Wardrobe

Select versatile pieces that mix and match:

• Stick to a colour scheme: Choose 2-3 complementary colours so everything coordinates
• Prioritise versatility: Each item should work with at least 3 other items in your bag
• Pack half, then remove more: Lay out everything you think you need, then put half back
• Plan outfits, not options: Instead of packing "just in case" items, plan specific outfits for each day

Choose Lightweight Fabrics

Not all clothing is created equal weight-wise:

• Merino wool: Lightweight, temperature-regulating, and odour-resistant (wear multiple days)
• Technical synthetics: Quick-drying and packable
• Tencel/lyocell: Lightweight, soft, and wrinkle-resistant
• Avoid: Heavy cotton, denim (one pair maximum), bulky sweaters

The Layering Strategy

Instead of packing heavy coats and sweaters, use layers:

1. Lightweight base layer
2. Mid-weight fleece or jacket
3. Packable down or synthetic puffer
4. Water-resistant shell

This system handles a wider range of temperatures with less total weight than individual heavy items.

The Weigh-As-You-Pack Method

Don't wait until you're finished packing to check your weight. Use your luggage scale throughout the process:

1. Weigh your empty suitcase: Know exactly how much "overhead" you're starting with
2. Set a target weight: Aim for at least 1-2kg under your limit to accommodate purchases during your trip
3. Weigh as you add items: Check after adding each category (clothes, shoes, toiletries, etc.)
4. Identify heavy items early: If you're approaching your limit before adding essentials, you know you need to remove something

Shoes: The Weight Killers

Shoes are disproportionately heavy. A pair of running shoes can easily weigh 600-800g, and hiking boots might top 1kg. Strategies for shoe efficiency:

• Three-shoe rule: Maximum of three pairs—one on feet, two in bag
• Wear your heaviest pair: Travel in your bulkiest shoes to save bag weight
• Choose versatile footwear: A good walking shoe that looks presentable for casual dining eliminates the need for multiple pairs
• Consider your activities: Do you really need formal shoes, or will clean sneakers suffice?

Toiletries and Liquids

Full-size toiletries are heavy and often unnecessary:

• Decant into travel containers: Most trips don't require 500ml of shampoo
• Use solid alternatives: Shampoo bars, solid deodorant, and toothpaste tabs save liquid weight and avoid liquid restrictions
• Buy at destination: Common items are available everywhere—don't pack a month's supply
• Hotel amenities: Shampoo, conditioner, and soap are provided at most accommodations

Packing Techniques That Save Space and Weight

Rolling vs. Folding

Rolling clothes is often more space-efficient and reduces wrinkles for casual items. However, structured items like blazers may fold better. Use a hybrid approach based on garment type.

Packing Cubes

While the cubes themselves add a bit of weight, they help you pack more systematically, see what you have, and resist overpacking. Compression cubes can reduce volume by up to 50% for bulky items like sweaters.

Fill Dead Space

Stuff shoes with socks or small items. Roll belts inside shirt collars. Use every cavity efficiently to maximise your space-to-weight ratio.

The Return Journey: Planning for Purchases

Many travellers pack perfectly for departure but forget they'll want to bring souvenirs home. Plan for this:

• Leave headroom: 1-2kg under your limit provides purchase flexibility
• Pack a foldable bag: A lightweight packable duffle can become a second carry-on for the return journey if needed
• Ship heavy items: For major purchases, international shipping may be cheaper than excess baggage fees
• Wear your purchases: That heavy jacket you bought? Wear it on the plane

Budget Airlines: The Carry-On Challenge

Flying Jetstar, Tigerair, or similar budget carriers with carry-on only requires advanced efficiency:

• 7kg is tight: You'll need to be ruthless—every gram matters
• Wear heavy items: Boots, jacket, and heavy jewellery go on your body, not in the bag
• Personal item strategy: Some airlines allow a personal item (handbag, laptop bag) in addition to carry-on—maximise this
• Weigh repeatedly: Check your weight before leaving home and be prepared to wear extra layers to the airport

Emergency Last-Minute Strategies

If you're at the airport and overweight, try these approaches:

• Redistribute: Move heavy items from checked to carry-on (or vice versa if checked is overweight)
• Wear it: Put on extra layers, fill coat pockets with heavy items
• Post items home: Australia Post Express has airport locations
• Leave behind: Sometimes an item's cost is less than the excess fee

Efficient packing is a skill that improves with practice. Start by investing in a good luggage scale and developing the habit of weighing throughout your packing process. Soon, you'll be breezing through check-in while others stress over excess fees—with money saved and a lighter load to carry through your adventures.

Written by James Mitchell

James is the founder of Best Scales Australia and a seasoned traveller who has packed for trips ranging from weekend city breaks to month-long international adventures. He's experienced both sides of the check-in scale and now helps others avoid the excess baggage trap.