Short answer
Most transit damage comes from three causes: the product moving inside the box, the box being too weak for the stack, and poor pallet presentation. Fix the internal fit first, then the board grade, then how the pallet is built and wrapped.
Start with movement
If a product can move more than a few millimetres, it will keep hitting the same corner for the whole journey. A right-sized box with a fitted insert usually removes more damage than upgrading the board.
The checklist
- Right-size the internal dimensions and remove the void.
- Cushion the corners and edges first, because that is where impacts land.
- Match the board grade to the stack height, not just the product weight.
- Seal with an H-pattern on heavy cartons rather than a single centre strip.
- Keep pallet loads square with no overhang, and anchor the wrap to the pallet.
- Use edge protectors and top caps on stacked or double-decked pallets.
- Label fragile and orientation marks clearly on two adjacent faces.
Test before you roll out
A drop test from the height your carrier actually handles at, on all six faces and a corner, will show you the failure point in ten minutes. We make free samples for exactly this, so you can break a few before you commit to a run.
Work out what damage really costs
Add the replacement product, the second carriage charge, the admin and the customer goodwill. Against that number, a stronger board grade or a fitted insert is almost always the cheaper option.
Frequently asked questions
- What causes most transit damage?
- Product movement inside an oversized box, followed by under-specified board for the stack height and poorly built pallets.
- Will you review our current packaging?
- Yes. Our free packaging review looks at how you pack today and returns costed alternatives with free samples.
- Do you supply edge protectors and top caps?
- Yes, along with strapping, corner boards and pallet stabilisation materials.
Think your packaging is bigger than it needs to be?
Send us your product dimensions and we’ll come back with a right-sized option. There is no minimum on stock lines, and bespoke corrugated runs can start from as little as one, but we will advise the most cost efficient run rate depending on size and board grade.
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