How Do You Prevent Shipping Damage

Most shipping damage should be dealt with before the goods leave the factory. Keep the product from moving inside the box, stop finished surfaces from rubbing together, use cartons and pallets that suit the real weight, keep the goods dry, inspect the finished packing, and make sure the cargo cannot shift during loading and transport.

Start With How the Product Can Be Damaged

Before you approve the packing, check these five points:

• Can the product move inside the carton?
• Can two products, parts, or accessories touch each other?
• Which part is easiest to break, bend, scratch, or crush?
• How much weight will the carton and pallet carry?
• Could moisture reach the product before or during shipping?

A painted metal part, for example, may be hard to break but easy to scratch. In this case, sleeves and fixed dividers can be more useful than simply adding more foam.

Write Packing Rules That Can Be Checked

Instructions such as “use export packaging” or “use a strong carton” are too vague. The supplier and inspector need requirements they can actually check.

A useful packing specification can include:

• units per inner box and master carton;
• product position inside the carton;
• individual bags, sleeves, or wrapping;
• dividers and inserts;
• corner and edge protection;
• carton dimensions;
• approved gross weight;
• carton sealing method;
• pallet size and stacking pattern;
• shipping marks and barcode position;
• moisture protection where needed;
• approved packing drawing or sample.

JS Sourcing’s guide to preparing a purchase order for a Chinese manufacturer also explains why packaging, carton quantity, labels, carton marks, and weight requirements should be written into the purchase documents instead of being agreed only by phone or chat.

Instead of writing:

Use enough protection.

write requirements such as:

• 12 units per master carton;
• each unit packed in one protective sleeve;
• one divider between painted surfaces;
• accessory bag fixed in the approved position;
• corner supports fitted as shown in the drawing;
• carton dimensions within the approved limits;
• gross weight within the approved limit;
• label placed on the specified side of the carton.

If something is easier to show than explain, use a photo or drawing.

Give the packing specification a revision number, such as PKG-24018 Rev. B. If the carton size, insert, pack quantity, or pallet arrangement changes, update the revision so the factory and inspector are working from the same version.

Keep the Product From Moving Inside the Box

Too much empty space gives the product room to hit the carton wall, another product, or a loose accessory.

Depending on the product, you can use:

• fitted corrugated inserts;
• molded pulp;
• foam blocks;
• partitions;
• trays;
• paper cushioning;
• fixed accessory compartments.

A simple shake check can help find obvious movement. But a carton that does not rattle is not automatically safe. It can still fail because of vibration, pressure from other cartons, or impact.

Try tilting the packed carton too. Some dividers stay in place when the carton is upright but slide when the box is turned.

Small accessories also need to be fixed. Screws, brackets, tools, cables, and adapters should not be able to move around and hit the main product.

JS Sourcing has also recorded a glassware case where the importer changed to custom foam inserts and the damage rate dropped from about 12% to below 2%. The point is not that every fragile product needs the same foam. The useful lesson is that fixing movement and support inside the carton can make a much bigger difference than simply using a thicker outer box. See the case in JS Sourcing’s landed cost guide.

Do Not Put Pressure on Fragile Parts

Check where the packaging touches the product.

Parts that often need extra attention include:

• corners;
• thin edges;
• glass sections;
• handles;
• hinges;
• legs;
• connectors;
• knobs;
• finished surfaces.

If a foam block presses directly against a weak connector, an impact may push the force straight into that connector. Where possible, let stronger parts of the product take the support load and leave some clearance around fragile parts.

For example, a machine component may have a strong metal housing and a small plastic connector on one side. Support the housing rather than using the connector as a support point.

Choose Carton Tests Based on the Problem

The number of corrugated layers does not tell you how well a carton will perform. A five-layer carton can still fail if the board, carton size, product weight, moisture level, or stacking method is wrong.

ECT measures the edgewise compression strength of corrugated fiberboard. TAPPI T 811 covers ECT testing for single-, double-, and triple-wall corrugated board.^[1]

ECT tells you about the corrugated board itself. It does not directly tell you how much load a finished packed carton can take.

Burst strength measures how well the board resists rupture. It is not the same as checking how much vertical pressure a finished box can handle.

Box compression testing checks how a completed shipping box or unit load performs under external pressure. ASTM D642 covers compression testing of shipping containers, components, and unit loads.^[2]

For a simple example, if five cartons weighing 20 kg each are stacked one above another, the bottom carton has about 80 kg of carton weight above it before vibration, humidity, handling, and other forces are considered.

This does not mean an 80 kg compression rating is enough. It shows why carton strength, carton weight, stack height, and pallet support need to be checked together.

Reduce Pack Quantity When the Carton Gets Too Heavy

Check the actual packed gross weight. Product weight alone is not enough because the carton, inserts, dividers, and accessories add more weight.

For example, if one metal component weighs 3.8 kg, 10 units already give:

3.8 kg × 10 = 38 kg

If the quantity is reduced to 6 units:

3.8 kg × 6 = 22.8 kg

The product load inside the carton is 40% lower.

These numbers are only a calculation example, not a recommended carton-weight limit. The useful point is that changing the pack quantity can sometimes fix a weight problem better than continually adding thicker board.

If the product is very heavy, has sharp edges, puts most of its weight on a small area, has an unstable center of gravity, or has long unsupported sections, an ordinary carton may not be enough. A reinforced pallet, crate, or wooden case may be more suitable.

Check What a Bigger Carton Does to Freight Volume

Extra protection can make the carton bigger, so check the effect on shipment volume before approving the change.

A carton measuring 60 × 40 × 30 cm has a volume of:

0.60 × 0.40 × 0.30 = 0.072 m³

If extra cushioning increases the height from 30 cm to 35 cm:

0.60 × 0.40 × 0.35 = 0.084 m³

The carton volume has increased by about 16.7%.

For 100 cartons:

• original volume: 7.2 m³;
• new volume: 8.4 m³;
• extra volume: 1.2 m³.

Do not remove protection the product needs. Just check that the larger carton is actually solving a damage problem rather than adding unnecessary CBM.

Make the Carton Size Work With the Pallet

Check the pallet size, condition, total load, stack height, carton position, straps, edge protection, stretch wrap, and forklift access.

Avoid having cartons hang over the pallet edge. The unsupported part of the carton is easier to crush or hit during handling.

Using a pallet much larger than the load can also waste shipping space.

Small carton-size changes can matter. Increasing one carton side from 390 mm to 410 mm is only 20 mm, but it may change how many cartons fit across a pallet.

Pay close attention to the bottom layer because those cartons carry the weight above them.

Do not assume an interlocking stack is always stronger. Different stacking patterns move the load through the carton walls in different ways.

Straps should hold the load without cutting into carton corners. Use edge protection where needed. Stretch film can keep cartons together, but it should not be the only thing holding a heavy or unstable pallet in place.

Make Sure the Goods Are Dry Before Packing

Moisture can weaken cartons, cause mold, damage labels, stain finished surfaces, and cause metal parts to rust.

The moisture may already be in the product, carton, pallet, or other packing material before loading. Temperature changes can also cause condensation inside a freight container. UNECE’s CTU Code explains how moisture in cargo and packing materials can contribute to condensation inside containers.^[3]

Before the shipment is sealed, check that:

• products are dry enough to pack;
• cartons are dry;
• pallets and dunnage are suitable for use;
• cartons have not been left in the rain;
• there is no visible water inside the container;
• there is no obvious leak.

For metal products, do not pack them immediately after washing or cleaning if moisture is still present.

Barrier bags, desiccants, or VCI materials may help depending on the product and route. But desiccant does not fix a wet product, carton, or pallet. Deal with the moisture source first.

Test the Pack You Will Actually Ship

Transport testing is useful when the product is fragile, the packaging is new, the cost of damage is high, or the shipment will face a lot of vibration, impact, or stacking pressure.

ASTM D4169 provides a way to test shipping units against a series of distribution hazards instead of relying on one simple test.^[4]

ASTM D4728 covers random vibration testing of filled shipping units and looks at the container, internal packing, closure, and contents together.^[5]

ISTA Procedure 3A is intended for individual packaged products of 150 lb (70 kg) or less moving through parcel delivery systems by air or ground.^[6] It is not a single test for every export carton.

Before testing, decide what counts as a failure. Depending on the product, that may include:

• the product no longer works;
• the housing cracks;
• the product bends permanently;
• a visible surface is scratched;
• an internal support breaks;
• the retail box is damaged beyond the agreed limit.

The test sample should match the real production pack as closely as possible, including carton construction, dimensions, inserts, product weight, pack quantity, accessories, sealing method, and pallet arrangement.

If an important part of the package changes later, check whether another test is needed.

Approve the Product Inside Its Final Packaging

Before mass production, check a fully packed sample.

Look at:

• where the product touches the insert;
• whether fragile parts have enough clearance;
• whether finished surfaces can rub;
• whether accessories are fixed;
• whether the product can move;
• actual packed carton weight;
• sealing method;
• label position.

For custom products, this can be handled as part of the product development and sample approval process.

If the packaging uses several inserts or accessories, give the factory photos showing the correct packing steps. This helps keep the packing method consistent between workers and production batches.

Check the Packing While Production Is Still Running

JS Sourcing’s During Production Inspection (DUPRO) is carried out when around 20%–80% of the order has been manufactured.

At this stage, check:

• carton dimensions and material;
• inserts and dividers;
• foam shape;
• pack quantity;
• product position;
• accessories;
• labels and carton marks;
• gross weight;
• differences between packaging batches.

The main advantage of checking at this stage is simple: if the factory has changed the insert, carton, label, or packing method, there is still time to correct the remaining production.

Open the Highest-Risk Cartons During PSI

JS Sourcing’s Pre-Shipment Inspection is carried out when at least 80% of the goods are manufactured and packed.

Open sample cartons and check:

• pack quantity;
• internal protection;
• carton dimensions;
• gross weight;
• accessories;
• labels and barcodes;
• shipping marks;
• carton sealing;
• pallet condition.

For mixed orders, make sure higher-risk packs are included in the inspection.

For example, if most SKUs use light cartons but one product has a much heavier or larger carton, that package should not be treated the same as the others.

PSI can find wrong packing, damaged cartons, missing protection, wrong quantities, and labeling problems before shipment. It cannot reproduce every vibration, impact, humidity change, or handling mistake that may happen later.

Do Not Load Into a Wet or Damaged Container

Check the empty container before the first carton or pallet goes inside.

Look at:

• the floor;
• walls and roof;
• doors and seals;
• visible water;
• strong or unusual odors;
• holes;
• sharp objects or exposed nails;
• residue from earlier cargo.

JS Sourcing’s loading inspection checks the container for cleanliness, dryness, and visible condition before loading begins.

Do not load moisture-sensitive goods into a visibly wet container. Once the container is partly loaded, problems on the floor or walls become much harder to see.

Load the Cargo So It Cannot Shift

JS Sourcing’s Cargo Loading Supervision checks quantity, packaging condition, labels, container condition, weight distribution, and cargo securing while the shipment is being loaded.

During loading, check:

• correct SKU and carton quantities;
• whether cartons are already damaged;
• pallet quantity;
• weight distribution;
• large gaps between cargo;
• unstable products or pallets;
• lashing, dunnage, blocking, or bracing where needed.

The International Maritime Organization notes that poor packing, overloading, and inadequate cargo securing can contribute to transport incidents.^[7]

Do not put heavy goods on top of weak cartons. UNECE’s CTU Code also says heavier cargo should not be stowed on top of lighter cargo and explains why cargo position affects the center of gravity of the transport unit.^[8]

Record the container number, seal number, carton quantity, pallet quantity, and loading condition. Take photos before loading, during loading, when the container is full, and after the doors are closed.

Use More Handling Protection for LCL Cargo

LCL cargo shares space with other shipments and goes through consolidation and deconsolidation.

JS Sourcing’s LCL shipping guide shows why carton dimensions, pallet dimensions, and packing choices matter when several shipments share the same transport chain.

For LCL cargo, pay extra attention to:

• outer-carton strength;
• corner protection;
• pallet protection;
• strapping;
• stretch wrap;
• clear shipping marks;
• moisture protection.

Palletizing can reduce loose-carton handling for fragile, high-value, irregular, or multi-carton shipments. But it can also increase CBM, so compare the extra protection with the extra freight volume.

Also think about what may be loaded beside your shipment. Lightweight cartons can be damaged when placed next to machinery, stone, metal parts, drums, sharp cargo, or heavy pallets.

Check Solid-Wood Packaging Before Export

Check wooden pallets, crates, and dunnage for:

• broken boards;
• exposed nails;
• weak blocks;
• poor load support;
• too much moisture.

ISPM 15 applies to wood packaging material made from raw wood used in international trade, including dunnage. It does not cover packaging made from wood processed in a way that removes pest risk, with plywood given as an example.^[9]

If you use solid-wood pallets, crates, or dunnage, check the destination requirements before shipping.

Record Damage Before Throwing the Packaging Away

Keep damaged cartons, pallets, foam, dividers, and other packing materials until you understand what happened.

For every damaged shipment, record:

• total units received;
• total cartons received;
• number of damaged cartons;
• number of damaged products;
• SKU;
• damage type;
• outer-carton condition;
• internal packing condition;
• pallet condition;
• packaging revision.

If the carton looks normal but the product is damaged, check the internal packing first. The problem may be movement, poor support, missing dividers, or loose accessories rather than outside impact.

Use the Damage Pattern to Find What Went Wrong

If the same damage appears across many cartons, check for a repeated problem in the packing method, production, pallet setup, or loading. If only one carton is affected, a one-off handling problem is more likely.

Do not automatically add more foam. Fix the part of the packing system that caused the damage.

Track the Damage Rate After Each Change

Track damaged products and damaged cartons separately.

Damaged unit rate = damaged units ÷ total units received × 100

Damaged carton rate = damaged cartons ÷ total cartons received × 100

Keep the SKU, supplier, production batch, shipping method, destination, and packaging revision with the damage record.

This lets you compare one packaging version with the next. If a new insert, divider, or corner support is introduced, check whether the same type of damage falls on later shipments.

The glassware case recorded by JS Sourcing is a good example: after the importer changed to custom foam inserts, the damage rate fell from about 12% to below 2%. That kind of before-and-after result is more useful than simply telling the supplier to “pack it better.”

Keep the Evidence You May Need Later

For serious damage, keep:

• approved packing specification;
• packaging revision;
• inspection report;
• packing photos;
• loading photos;
• container and seal details;
• receiving photos;
• damaged cartons;
• internal packaging;
• damaged products;
• carton and pallet counts;
• relevant transport documents.

A crushed outer carton points to a different problem from an undamaged carton with a broken product inside. Keep the packaging until the cause is clear.

Cargo insurance may cover part of the financial loss, but it does not prevent physical damage. For valuable shipments, check the insurance coverage and evidence requirements before shipping.

Check These Items Before Releasing the Shipment

Finally

Before releasing the shipment, check that the factory is using the approved packing version, the carton weight and internal protection are correct, and the goods are dry. JS Sourcing’s DUPRO is carried out at about 20%–80% production, while PSI is carried out when at least 80% of the goods are manufactured and packed. Before loading, check the container, cargo quantity, packaging condition, weight distribution, and securing. After delivery, keep damaged packaging and record the damage rate by SKU and packaging revision. The aim is to find what actually failed and fix that part before the next shipment.