Packaging is not “to make it look nice,” and not “so it somehow makes it there.” It’s engineered protection for cargo in an environment where it gets shaken, squeezed by neighboring pallets, sometimes dropped, caught on the edge of forklift forks, dragged over a ramp, and left in a warehouse under humid air. And yes, the cargo doesn’t care that you tried your best. If the box is weak—it’s weak.
The most expensive logistics mistakes often start with saving on small things: thin cardboard, no corner protection, incorrect stretch wrapping, “we’ll put the label on later,” missing “this side up,” and ignoring moisture for sea transport. Then it turns into damage, mis-sorts, returns, disputed claims, and missed deadlines. In this article we’ll break down packaging requirements, a clear labeling system, practical approaches to material selection, and checklists that actually help.
What it is: the smallest physical unit that is counted and moved: a box, bag, crate, pallet, drum.
How it’s measured: number of pieces, weight per piece, dimensions per piece.
Why it matters: “10 boxes on a pallet”—is that 10 pieces or 1 piece? For different shipping schemes the answer differs. If you hand it over as a pallet—label the pallet. If as separate boxes—label each box.
What it is: consumer packaging is for the end customer; transport packaging is for shipping and warehouse handling.
How it’s measured: strength, protection from impact and moisture, compression resistance, stackability.
Why it matters: a “manufacturer’s box” is often not designed for 2–3 transloads and top load pressure—especially in LTL.
What it is: the ability of a shipping unit to withstand top pressure during storage/stacking.
How it’s measured: allowable stack height/load, box rigidity, use of dunnage/crating.
Why it matters: at a terminal your cargo may end up at the bottom under other pallets. “But we asked them not to stack on top” is not a technical specification.
What it is: how stable the load is on a pallet and how it’s fixed: stretch film, lashing straps, corner protectors, anti-slip sheets.
How it’s measured: no play, stability when tilted, stretch film integrity after forklift movement.
Why it matters: a pallet that “moves” is a pallet that will eventually fall. Not out of spite. Out of physics.
What it is: information that lets you uniquely identify what the cargo is, where it’s going, and how many pieces should be in the set.
How it’s measured: presence of a unique identifier (order/batch number), consignee details, “piece/total pieces,” handling marks.
Why it matters: 80% of “missing pieces” aren’t mysterious portals—they’re weak labeling and mis-sorting.
What it is: “this side up,” “fragile,” “keep dry,” “do not tip,” “center of gravity,” etc.
How it’s measured: correct placement and readability (not under stretch wrap, not on a seam, not only on one corner).
Why it matters: it doesn’t guarantee perfect handling, but it sets rules and helps with claims. Without marks, you make your own life harder.
| Risk type | What protects against it | Common mistake |
|---|---|---|
| Impact/drop | Dunnage, corner protectors, rigid box/crate | Empty “air” voids inside |
| Top compression | Strong box, correct stacking, crating | Weak cardboard + tall pyramid stacking |
| Moisture | Film, moisture barrier, bag/liner, desiccants | Unprotected cardboard for long storage/sea transport |
| Mis-sort | Unique label on each piece | Identical “nameless” boxes |
| Load shift on pallet | Stretch wrap, straps, corner protectors, anti-slip | “For show” wrapping with no tension |
When it fits: cargo goes in one truck from the shipper’s warehouse to the consignee, with no terminals and sorting; the cargo is not extremely fragile; conditions are stable.
Pros: fewer operations = lower damage risk; you can use “lighter” transport packaging (within reason).
Limitations: even in FTL there is forklift loading/unloading, and cargo may sit in a warehouse—packaging still must be strong.
Risks: saving on securing inside the vehicle; no blocking/bracing; incorrect loading with a wrong center of gravity.
When it fits: consolidated freight, multiple transloads, terminals, long routes, high mis-sort risk.
Pros: noticeably lower damage risk; stronger evidence base for claims; fewer losses from “minor” defects.
Limitations: more expensive and heavier; increases volume (and the tariff may rise).
Risks: reinforcing packaging without optimization can turn cargo into “expensive air” and kill the economics. You need balance.
When it fits: glass, electronics, instruments, pharma, chemicals—anything that doesn’t like impact, moisture, or temperature.
Pros: higher protection; compliance with carrier and insurer requirements; fewer disputed cases.
Limitations: requires standards and staff training; sometimes certified packaging is required.
Risks: improper “DIY” crating or incorrect ventilation/moisture protection (e.g., condensation) can turn packaging into the problem source.
Scenario 1: initial data—LTL shipments to regions; “crushed corners” happen regularly and mis-sorts occur. Actions—added corner protection, reinforced the box, made palletizing mandatory, implemented “order + piece/total pieces” labeling and photo evidence of each piece before dispatch. Result—damage and disputes decreased: the cargo started surviving transloads, and mis-sorts became easier to track.
Scenario 2: initial data—FTL shipping of a large batch, but sometimes the load “moves” inside the trailer and gets damaged. Actions—added securing (straps/bracing), changed the loading pattern, introduced “center of gravity” control, wrote requirements for the carrier, and recorded loading photos. Result—shift-related damage disappeared. We’ve worked in this field for over 13 years, and sometimes the biggest lever isn’t “a new carrier,” but two straps in the right place.
1) Do you always need to palletize?
Not always, but often it reduces damage and speeds handling. In LTL, palletizing is almost always justified because it lowers crushing and mis-sort risk. In FTL, you can sometimes ship boxes, but only if packaging and securing ensure stability.
2) What minimum labeling standard would you recommend?
A unique order/batch number, consignee/city, piece number and total pieces (e.g., 4/12), plus basic handling marks (“this side up,” “fragile,” “keep dry”) when needed.
3) How do you know packaging is “enough” and you didn’t overdo it?
Look at statistics: damage rate, repacking surcharges, tariff increase due to volume, and packaging cost itself. Adequate packaging is the one that reduces total loss and doesn’t turn the cargo into expensive air. Balance, not heroics.