Packaging & damage prevention

Package your cargo to survive the journey, not just the shelf. Use strong double-wall boxes, cushion fragile items, fill empty space, and label clearly. This protects your goods and your ability to claim — insurers routinely deny claims caused by poor packaging or a failed seal, so it's worth getting your supplier to pack properly before goods leave the factory.

Many buyers never think about packaging during the purchase negotiation, assuming factory packing is good enough for transit. It often isn't. If you'll ship repeatedly, it pays to understand what packaging you're being given and to specify better where needed. Two things are at stake: whether your goods arrive intact, and whether a cargo insurance claim will pay out if they don't.

The main job of packaging is to shield goods from water, impact, heat, and rough handling.

• Use quality double-wall boxes. They should hold their contents' weight securely.

• Tape properly. Use durable plastic tape at least 2–3 inches wide for light boxes, and reinforced tape at least 3 inches wide for heavy boxes. Don't use masking tape, cellophane tape, or duct tape.

• Wrap fragile items individually. Cushion each fragile item in bubble wrap or foam padding at least two inches thick.

• Keep products off the walls. Items shouldn't touch the inner cardboard. Use at least two inches of padding (foam, loose fill, kraft paper, or air pillows) around the goods, fill any gaps, and stop movement in transit.

• Don't overpack. An over-stuffed box fails under pressure.

• Guard against moisture. Bag anything sensitive to dirt or damp in plastic. For moisture-prone goods like textiles (which can grow mold in a container), pack a desiccant to absorb humidity.

The master carton is the outer box that gets stacked, dropped, and crushed:

• Wrap sharp edges. Seal or wrap protrusions on irregular items so they don't pierce the carton.

• Fill empty space. Pack out any voids so shock is absorbed by the packaging, not your product.

• Make them strong. Master cartons must bear the weight of cartons stacked on them and survive a drop. If you ship to a fulfillment center, follow its corrugation guidelines — and when in doubt, use the most heavily corrugated walls available.

• Number the cartons. Number each master carton before it's palletized.

If you ship to Amazon FBA, cartons and pallets must also follow Amazon's requirements.

Different modes reward different packing:

• Air freight is priced mostly on volume (chargeable weight), so minimize wasted space — tighten the product inside the carton and the cartons against each other. Avoid any unnecessary packaging, which costs you directly in air freight.

• Ocean freight has more room but rougher handling — unpredictable seas and weight shifts can cause containers to buckle. Weight, not volume, usually drives the cost, so favor uniform, standard-sized boxes that stack cleanly and stay put.

Gaps inside the retail product packaging waste volume and can cost you freight. Changing the product packaging is harder than changing the shipping carton — it can mean new tooling at the supplier — but if your order volume is high, a supplier is more likely to accommodate you. Start by tightening the shipping carton, which is the easy win.

Because most cargo is consolidated with other shippers' goods unless it fills a whole container, clear labeling is essential — see Cartons: markings, pallets & fitting. If your goods are prone to theft, avoid outer labels that advertise what's inside. If a shipment is damaged in transit, your packaging is one of the first things an insurer reviews, so document it well.

• Cartons: markings, pallets & fitting

• How much fits in a container & how to load it

• Why insure your cargo

• Chargeable weight explained

• Freight & shipping glossary