In the packaging and distribution industry, getting products from point A to point B is only half of the equation when it comes to success. It’s also important to ensure that your products arrive at their final destination in one piece. In many cases, packaging items in a right-sized box will prevent them from shifting around during transit, and provide adequate protection to keep them safe and secure. However, fragile, valuable, or odd-shaped items may often need extra protection for the journey.

‍In this blog, we’ll discuss the different types of protective packaging for various products, and how to ensure your packaged items arrive safely to their destination, while using a minimal amount of packaging material.

Protective Packaging for Large Items

For larger items such as doors, windows, cabinets, and furniture, it’s crucial that the product arrives at the distributor or customer with minimal damage. This can be achieved in several ways:

Special coated corrugated cardboard can be used to reduce friction and scuffing as products rub against the inside of the box during transit. 

The outer box design can be constructed to include air cells, providing a buffer that holds the product in place. 

Corner and edge protectors, made from foam, corrugated cardboard, or pulp, can be added into the box to protect items like cabinets from chipped edges and smashed corners.

Protecting Odd-Shaped Products

Odd-shaped products and multi-item orders often create air gaps inside the box, leaving room for items to shift around or rub against each other during transit. Void fill material, such as packing peanuts and plastic air pillows, are often used to fill the extra space in these boxes. However, plastic items like these can be harmful to the environment, ending up in landfills and oceans, and breaking down into microplastics that contaminate our food, water, and even the air we breathe. More sustainable options, like crumpled or shredded paper, can still fill these gaps and cushion the products just as effectively, while minimizing the impact to the health of our planet. 

Cushioning is another form of protective packaging used for valuable and odd-shaped products. Available in various forms such as foam sheets, peanuts, foam-in-place, and air bubble wrap and pillow, these solutions hold items in place inside the shipping box to prevent damage. For a more environmentally-friendly cushioning option, engineered bubbles, paper, and corrugated inserts can be used to block and brace items as well. 

Choosing the Right Protective Packaging

When deciding on the best protective packaging, consider the following questions: 

What type of product is being shipped? Is it square, heavy, fragile, or large? 

Think about the shipping method: Will it be shipped via parcel, air, or local delivery? 

Sustainability is also important: Should the materials be recyclable, compostable, or biodegradable? Do end consumers care about sustainability? 

Evaluate the balance between cost and function: Is it worth investing in the most protective, potentially expensive packaging solution for your business? 

Check for any protective packaging regulations that need to be met. 

Finally, determine if your products need custom solutions to prevent damage.

The Importance of ISTA Testing

ISTA (International Safe Transit Association) testing is crucial for validating the effectiveness of protective packaging. These tests simulate transportation conditions like drops, vibrations, and compression, ensuring that packaging can withstand real-world scenarios. ISTA testing must be conducted by a certified lab. 

Using protective packaging offers several benefits. It reduces returns and replacements by minimizing damage, which saves costs. Additionally, ensuring products arrive in good condition improves customer satisfaction and enhances brand reputation. 

To learn more about what type of protective packaging is best for your products, or to get information about custom protective packaging solutions, reach out to a Packsize representative today for an evaluation.