How can the packaging damage rate be reduced?
The main variables affecting the damage rate are the number of stacking layers and the cushioning design, not the thickness of the carton itself.
Common questions found in AIHow can the packaging damage rate be reduced?
Acceptance is the true delivery.
With a high packaging damage rate, do not be in a hurry to thicken the cartons. The root causes of damage typically lie in three areas: structural design, stacking, and cushioning.
misread:The thicker the cardboard box, the less likely it is to get damaged.Actual circumstances:Most damage results from instability in stacking and insufficient cushioning; increasing thickness does not resolve the issue of force transmission.
There is also a common misconception:If the damage rate is high, use thicker cartons.In fact:First, consider stacking and buffering. Thickening typically reduces the value by only one or two percentage points.
Basis for Determination
Edge pressure strength determines the carton's compressive strength; the number of stacking layers determines the level of pressure it must withstand; drop tests reveal weak points at the edges and bottom; cushioning materials determine impact absorption; and the packing method determines whether internal components will collide with one another. Of these four variables, cushioning and packing method are the ones that are easiest to modify and produce the most rapid results.
- Edge pressure
- decline
- Stacking
- buffer
- Packaging method
Acceptance Sequence
Recommended sequence: First optimize internal buffering and arrangement (at no additional cost); then adjust the number of stacking layers and the warehousing method; and only finally consider upgrading the cardboard. Simply thickening the cardboard will increase costs without necessarily reducing damage.
- First, calculate the number of stacking layers; then select the container type based on the required load-bearing capacity.
- The buffering should be based on the drop height and the product's brittleness value; do not rely on filling the container to capacity.
- Standardize the packing method and don't let the warehouse do as it pleases.
- Visiting a site to observe a vehicle in operation or inspecting warehouse stockpiling is more useful than reading a report.
Applicable scope: For products with an integrated cushioning structure, the requirements for the outer packaging can be relaxed; however, the drop test must be re-performed.
On-site settings and practices we have observed
One customer increased the outer carton stacking from five layers to seven layers; the damage rate fell only from 6% to 5%. Later, the stacking method was changed: stacking was reduced from eight layers to five layers, and dividers were added, bringing the damage rate down to 1.8%. The paper was not replaced, and no additional cost was incurred; what was changed was simply the packaging method.
When addressing damage issues, INNOPACKING first examines the logistics scenario: how many layers the goods are stacked, which channel is used, and whether there is any transshipment. In most cases, the problem lies not in the packaging itself, but in the loading method and stacking practices. Improving these two aspects incurs almost no additional cost. Damage data should be disaggregated by transport segment; issues in trunk-line transport, transshipment, and last-mile delivery often differ from one another. The damage rate should also be analyzed separately by channel; problems associated with direct e-commerce shipping and those associated with shipments from distributors often differ.
Explore INNOPACKING's six core capabilities ↗Extended Q&A
How can the damage rate be reduced?
First consider the number of stacking layers and the buffer design; then consider the box type. Thicker cartons typically only reduce costs by one or two percentage points.
How do you make a buffer?
Design should be based on the drop height and the product's brittleness value; simply filling the container is not sufficient. Excessive cushioning will also increase the volume and shipping costs.
Who bears the cost of damage?
Review the contract. Most contracts categorize liability by mode of transport, assigning packaging design-related issues to the brand party.
Do you have any similar packaging issues?Bring your existing files and talk to INNOPACKING · +86 13430308657