Packing expert warns Ryanair travellers against overpacking their bags despite new larger personal item dimensions, and shares cardboard trick to stay compliant
Ryanair
Ryanair passengers have been urged to pack a piece of cardboard in their hand luggage following a change the airline implemented last summer.
The budget carrier expanded its ‘personal bag’ allowance by 20% in line with new EU regulations.
From September 2025, travellers flying on a basic fare can bring a bigger bag on board, with dimensions up to 40cm x 30cm x 20cm, at no extra cost. The bag must weigh under 10kg and fit beneath the seat in front.
With the updated bag sizes now active, packing specialist Tom Schott from Schott Packaging is warning Irish holidaymakers about a potentially expensive error, as he suspects the enhanced allowance could encourage Ryanair passengers to overstuff their bags.
Tom explained: “The new dimension is a game-changer, but only if you use it wisely.
Ryanair increased its cabin bag allowance in 2025(Image: Nuria Gonzalez Sanchez via Getty Images)
“The mistake is to simply cram more in. The real victory for passengers is using that volume to pack with structure. A well-packed bag is a compliant bag.”
Among Tom’s various recommendations to prevent this is including some cardboard. He said: “Soft bags lose volume. A lightweight, snug-fitting cardboard box inside your bag provides a rigid frame, allowing you to use every corner and prevent the bulge that attracts gate staff.”
He further recommends using sealable bags to optimise space, sorting items into smaller sections, and safeguarding valuables. Tom continued: “Place a small, sturdy box in the centre of your bag, cushioned by clothes.
“This creates a crush-proof zone for chargers, adapters, and toiletries, preventing damage and leaks.”
Holiday-goers are also encouraged to “pre-plan your bag”, with Tom suggesting you lay out all your items on the floor within a 40cm x 30cm outline beforehand, reports the Mirror.
This “provides a real-world view of what fits and helps you assemble your packed modules logically and quickly.”
Tom continued: “These aren’t just clever tricks, but core principles of efficient packing. By applying them, you can confidently pack that extra outfit and still breeze through the boarding gate”.
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