Packaging that survives the journey

Published 7 September 2025 · ~6 min read · By Middle Earth Consulting AB

Ocean freight is rough, stacked, and humid. The fix is a packaging baseline that’s simple to run: correct cartons, protection where it matters, good labels, and a quick test routine before you ship.

Packaging that survives the journey

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Start with the carton: strength, size, and stack

  • Board grade: choose by weight & stack height. Typical: 5-ply for heavier SKUs; test for ECT (edge crush).
  • Right-sizing: reduce air gaps to stop collapse and cut dunnage cost.
  • Stack plan: set max height per pallet based on ECT and voyage duration.

Protect the product, not the air

  • Corner & edge protection: L-profiles where impacts occur most.
  • Suspension or foam-in-place: for fragile or high-value parts.
  • Internal trays/dividers: keep components from rubbing or puncturing.

Humidity and corrosion control

Containers sweat. Control moisture so boxes don’t soften and metals don’t rust.

  • Desiccants: size by container volume and climate route.
  • Barrier bags/VPCI: for metal parts, seal with correct heat time.
  • Tape & glue: use water-resistant adhesives for seams and labels.

Pallets that arrive intact

  • Pallet choice: heat-treated (ISPM-15) wood or high-strength paper pallets.
  • Overhang = damage: cartons must sit fully on the deck; adjust pack pattern.
  • Wrap & strap: top cap + corner posts + stretch wrap; add two cross straps for long routes.

Labels that speed up receiving

  • Readable at a glance: SKU, PO, quantity, weight, carton X of Y, country of origin.
  • Orientation: always on two adjacent sides; barcodes scannable without turning the pallet.
  • Handling icons: top-load only, keep dry, center of gravity when relevant.

Quick tests that prevent slow problems

Drop & vibration

  • ISTA-1A style drop sequence for parcel/carton shipments.
  • Simple shake test: 30–60s hand-vibration for small cartons.
  • Photo the result and note damage points to update packaging.

Compression & clamp

  • Carton compression or a practical stack test for 24–48h.
  • Clamp trial at the forwarder if using clamp trucks.
  • Log pass/fail with board grade and humidity on the report.

What to document in every PO

  • Board grade, inner protection, desiccant spec, and pallet pattern.
  • Max pallet height & weight; wrap/strap method; labels to print.
  • Photos of good pack and good pallet, stored with the PO.

Common pitfalls

  • Using single-wall where 5-ply is needed for stack pressure.
  • Overhang on pallets leading to corner crush during handling.
  • Labels only on one side, causing slow receiving and mis-scans.
  • No humidity plan on winter routes, cartons arrive soft.

Baseline checklist you can apply this week

  1. Pick board grade by weight + stack; confirm ECT.
  2. Add corner protection; right-size internals to remove air gaps.
  3. Define pallet pattern, overhang = zero, add top cap & straps.
  4. Print two-side labels with SKU/PO/qty/origin + barcode.
  5. Run a carton drop & 24h stack test; update pack if needed.

Need help reducing damage rates?

We design packs, choose materials, and run quick tests with your factory, then lock a photo playbook so every repeat order ships with the same, proven protection.

Request a packaging review