Ryanair travellers are being urged to pack a piece of cardboard in their hand luggage following a declaration the carrier made last summer. The low-cost airline expanded its 'personal bag' dimensions by 20% in line with new EU rules.

From September 2025, passengers flying on a basic ticket were able to take a larger bag onboard, measuring up to 40cm x 30cm x 20cm, without facing extra fees. The bag must weigh under 10kg and fit beneath the seat in front of you, reports the Mirror. With the revised bag measurements now active, packing specialist Tom Schott from Schott Packaging is warningholidaymakers about a potentially expensive error, as he suspects the enhanced allowance could encourage people to overstuff their bags. Tom said: "The new dimension is a game-changer, but only if you use it wisely.

"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."

Amongst Tom's numerous recommendations to prevent this is to include some cardboard. He explained: "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 also proposes using sealable bags to optimise space, arranging items into smaller sections, and safeguarding valuables. Tom added: "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."

Holidaymakers are also advised to "pre-plan your bag", with Tom suggesting that you organise all your items on the floor within a 40cm x 30cm outline beforehand, as 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".