It aims to select environment-friendly materials for window air conditioner packaging and optimize the inner packaging structure to make the whole package dimensions conform to maximum loading capacity and pass the clamping force test and enable the packaging to be suitable for manipulator handling, loading and unloading. The new design of window air conditioner fitted regular transport environment from aspect of both material and structure and passed the packaging test for foot stepping, dropping, stacking and transporting. Its reliability was also demonstrated. Besides, it was suitable for manipulator handling and passed the clamping test. This structure design not only saved energy and resources, but also used less packaging materials and could be recycled. It could also pass all kinds of packaging tests, especially the clamping test. It could be applicable to window air conditioner that was subject to mechanical automated handling. In conclusion, product packaging structure can neither be excessively designed, nor poorly designed. The application of green packaging materials, new structures and new technologies will be able to protect the product.