How to Prevent Products from Shifting InsideHow to Prevent Products from Shifting Inside Boxes
Products can shift inside boxes when there is too much empty space, insufficient internal support or unsuitable packaging around the product.
Movement may occur during forklift handling, vehicle vibration, sudden braking, container movement, loading, unloading and repeated handling.
To prevent products from shifting, businesses should use correctly sized boxes, secure the product with suitable inserts or dividers, distribute weight evenly and fill only the necessary empty space.
The complete packaged product should also be tested under conditions that reflect the expected distribution journey.
Why Do Products Shift Inside Boxes?
Products shift when the packaging does not hold them securely in their intended position.
The movement may be small at first. However, repeated vibration and impact throughout transportation can cause the product to move further from its original position.
Common reasons include:
Boxes that are too large
Insufficient internal packaging
Incorrect product orientation
Large empty spaces
Loose dividers
Weak cushioning materials
Uneven weight distribution
Heavy components that are not secured
Weak carton boxes
Damaged packaging
Incorrect box closure
Moisture-weakened materials
Changes to the product without updating the packaging
Movement may occur in any direction, including forward, backward, sideways, upward or downward.
A suitable packaging design should control movement in all directions that may occur during handling and transportation.
What Happens When Products Move Inside Boxes?
Product movement can create repeated contact between the product and the internal surfaces of the box.
This may result in:
Scratches
Dents
Broken components
Cracked products
Damaged surfaces
Bent parts
Loose components
Damaged electronics
Crushed packaging
Torn cartons
Product deformation
Customer complaints
Rejected deliveries
Replacement shipments
Movement can also change the weight distribution inside the box.
A product that moves toward one side may cause the package to become unbalanced and more difficult to lift, stack or transport safely.
Why Is Empty Space a Packaging Risk?
Empty space gives the product room to move.
When the vehicle accelerates, brakes or turns, the product may continue moving inside the package until it contacts the box wall or another component.
The greater the movement distance, the greater the potential impact.
Empty space may also cause:
Uneven stacking pressure
Carton deformation
Internal packaging collapse
Product-to-product contact
Poor weight distribution
Unstable pallet loads
Additional cushioning requirements
The objective is not necessarily to remove every small space.
The packaging should provide enough clearance for suitable protection while preventing uncontrolled product movement.
How to Prevent Products from Shifting Inside Boxes
Use the Correct Box Size
The outer box should be selected according to the product dimensions and required protective materials.
A box that is too large creates excessive empty space.
A box that is too small may place pressure on the product or provide insufficient room for cushioning.
Before selecting a box, measure:
Product length
Product width
Product height
Product weight
Protruding components
Fragile areas
Required clearance
Internal support thickness
Number of products per box
The final box dimensions should include the product and all necessary internal protection.
Do not select the box based only on the product’s external dimensions.
Reduce Unnecessary Empty Space
Empty space should be reduced through packaging design rather than simply adding large amounts of random filling material.
Possible methods include:
Using a smaller box
Changing the product orientation
Adding custom inserts
Using dividers
Installing internal supports
Adding layer pads
Using honeycomb board
Adding protective profiles
Using suitable cushioning
Combining multiple products efficiently
The solution should prevent movement while maintaining sufficient protection against impact and compression.
Use Custom Packaging Inserts
Custom inserts are designed according to the shape and dimensions of the product.
They can hold the product in a fixed position and prevent it from moving toward the box walls.
Custom inserts may include:
Paperboard inserts
Honeycomb-board inserts
Corrugated inserts
Folded carton structures
Support blocks
Product trays
Partitions
Frames
Protective profiles
Custom inserts can be particularly useful for products with irregular shapes, fragile components or specific support points.
A suitable insert should support the strong areas of the product rather than placing pressure on vulnerable components.
Use Dividers and Partitions
Dividers separate multiple products inside the same box.
They can help prevent products from colliding with one another during handling and transportation.
Dividers may be arranged as:
Vertical partitions
Horizontal layers
Cross dividers
Individual cells
Interlocking grids
Product sleeves
Custom compartments
Each compartment should fit the product closely enough to control movement.
Loose dividers may move together with the products and provide limited protection.
The divider material should also have sufficient strength for the product weight and transportation conditions.
Use Honeycomb Board for Internal Support
Honeycomb board is a paper-based material with a cellular internal structure.
It can be converted into panels, blocks, dividers, layer pads and custom protective components.
Eltete describes its honeycomb board as a lightweight material with cushioning properties, compression strength and rigidity for transport-packaging applications. It can also be cut or shaped into components designed around the product.
Honeycomb board may be used to:
Fill controlled spaces
Separate products
Support heavy areas
Protect flat surfaces
Create internal frames
Produce custom inserts
Prevent vertical movement
Create layer pads
Support box walls
The thickness and strength should be selected according to the product weight, dimensions and required protection.
Use Edgeboard Inside the Box
Edgeboard is commonly used around the external corners of palletised loads, but it may also be used inside boxes.
Internal edgeboard can help:
Reinforce box corners
Hold products in position
Create separation
Support vertical loads
Improve stacking strength
Protect product edges
Eltete states that Edgeboard can be used externally on pallet corners or inside boxes to provide additional stacking strength.
The edgeboard dimensions and position should match the packaging design.
It should not apply excessive pressure to fragile product surfaces.
Use Suitable Cushioning Materials
Cushioning absorbs impact and reduces the forces transferred to the product.
Suitable cushioning may include:
Paper-based cushioning
Honeycomb structures
Corrugated pads
Folded paperboard
Protective pads
Custom supports
Other application-specific materials
Cushioning should be selected according to:
Product weight
Fragility
Impact sensitivity
Drop height
Transportation method
Number of handling points
Package dimensions
Storage conditions
Soft cushioning that works for a lightweight product may compress excessively under a heavy product.
A heavier product may require stronger structural support rather than additional soft filling material.
Secure Heavy Components
Heavy products or components can create significant force when they move inside a box.
They should not rely only on loose void-fill material.
Heavy components may require:
Rigid supports
Custom blocks
Internal frames
Reinforced bases
Strapping within the box
Mechanical restraints
Multiple support points
Protective profiles
Custom-designed transport boxes
The support system should prevent movement while distributing the product weight across strong areas of the packaging.
The box base must also be strong enough to carry the concentrated load.
Protect Products from Contacting Each Other
When multiple products are packed together, they should not be allowed to collide.
Product-to-product contact may cause:
Scratches
Surface damage
Broken corners
Dents
Cracked components
Damaged coatings
Noise during transportation
Possible solutions include:
Individual compartments
Dividers
Layer pads
Product sleeves
Protective wrapping
Corner profiles
Honeycomb separators
Custom trays
Each product should remain separated throughout expected vibration and handling.
Small gaps may become larger when dividers compress or move, so the complete arrangement should be tested.
Use Layer Pads
Layer pads are flat sheets placed between product layers.
They may help:
Separate products
Distribute weight
Reduce surface contact
Improve stacking
Prevent vertical movement
Stabilise product layers
Protect the top and bottom surfaces
Layer pads may be produced from corrugated board, honeycomb board or other suitable materials.
The material should have sufficient compression strength for the weight placed above it.
A weak layer pad may bend or collapse, allowing products to move.
Control Movement in Every Direction
Packaging should control movement in six main directions:
Forward
Backward
Left
Right
Upward
Downward
A package may prevent sideways movement but still allow the product to bounce vertically.
Vertical movement may occur when:
The box is dropped
The shipment passes over uneven roads
The package is moved quickly
The internal support compresses
There is excessive headspace above the product
Top pads, internal frames or correctly designed inserts may be required to prevent upward movement.
The product should remain secured without being compressed excessively.
Distribute Weight Evenly
Uneven weight distribution can cause the product and internal packaging to move toward one side.
It may also weaken the carton and create an unstable package.
When packing multiple products:
Place heavier products at the bottom
Distribute weight across the box base
Avoid placing all heavy items on one side
Keep the centre of gravity as central as possible
Use supports beneath concentrated loads
Avoid unsupported heavy components
Confirm the correct box orientation
Heavy products should not be placed above fragile or lightweight products unless the packaging has been designed for that arrangement.
Use the Correct Product Orientation
Some products are stronger in one orientation than another.
The correct orientation may help:
Improve stability
Reduce movement
Protect fragile components
Distribute weight evenly
Reduce package dimensions
Simplify internal support
Improve stacking performance
Products with high centres of gravity may become unstable when packed upright.
Products with sensitive surfaces may require a specific side to face upward.
The approved orientation should be clearly communicated through packing instructions and package labels.
Wrap Products Individually When Necessary
Individual wrapping may help protect product surfaces and reduce direct contact.
It may be suitable for:
Painted components
Polished surfaces
Furniture parts
Metal products
Glass items
Electronics
Automotive components
Fragile products
Individual wrapping alone may not prevent movement.
The wrapped product should still be held securely using inserts, dividers or supports.
Wrapping provides surface protection, while the internal packaging system controls position and movement.
Strengthen the Bottom of the Box
The bottom of the box supports the complete product weight.
If the bottom bends or collapses, the product may move even when the internal packaging is correctly designed.
The box base may require:
Additional corrugated pads
Honeycomb panels
Reinforced bottom flaps
Paper pallet runners
Support blocks
Double-wall construction
Custom load-bearing components
The required strength depends on:
Total product weight
Weight distribution
Box dimensions
Storage duration
Stacking conditions
Humidity
Handling method
Heavy products should be supported by a suitable load base rather than relying only on the carton walls.
Use a Strong Outer Box
The outer box must maintain its dimensions throughout the distribution journey.
A weak box may bulge, crush or lose its shape.
This can create additional space around the product and allow movement.
Select the box according to:
Product weight
Package dimensions
Stacking height
Storage duration
Transportation method
Humidity exposure
Number of handling points
Internal packaging design
A box material specification alone does not confirm that the complete package will protect a specific product.
ISTA explains that box-material requirements do not necessarily address product damage or complete protection throughout every transportation method.
The complete packaged product should therefore be evaluated rather than relying only on the box specification.
Close and Seal the Box Correctly
An incorrectly sealed box may open, deform or lose structural strength during transportation.
Use a closure method that matches:
Box weight
Carton construction
Transportation duration
Handling conditions
Storage environment
Customer opening requirements
Possible closure methods include:
Suitable packaging tape
Adhesive systems
Strapping
Staples where appropriate
Interlocking carton designs
Custom fasteners
The top and bottom flaps should remain securely closed.
Tape should be applied evenly across clean and dry carton surfaces.
Do not rely on damaged, dusty or moisture-affected tape areas.
Avoid Using Loose Void Fill for Heavy Products
Loose void-filling materials may move away from heavy products during vibration.
They may also settle at the bottom of the box, leaving empty spaces around the sides or top.
For heavy products, use structured packaging such as:
Custom inserts
Honeycomb supports
Corrugated frames
Rigid dividers
Support blocks
Reinforced bases
Protective profiles
Loose fill may be suitable for certain lightweight products, but it should not replace proper structural support.
Prevent Internal Packaging from Moving
The internal packaging must also remain fixed inside the box.
An insert that slides within the carton cannot reliably hold the product in position.
Internal components should:
Fit the box dimensions correctly
Lock into the carton structure
Remain stable during vibration
Support the intended product areas
Resist expected compression
Maintain their shape
Avoid creating sharp pressure points
Interlocking or folded structures can help keep inserts in position without requiring excessive additional material.
Consider Product Shape
Irregular products may be more difficult to secure than rectangular products.
Examples include:
Curved components
Machinery parts
Pipes
Furniture pieces
Automotive components
Products with handles
Products with protrusions
Asymmetrical products
Irregular products may require multiple support points or customised profiles.
The packaging should prevent the product from:
Rolling
Rotating
Tilting
Sliding
Bouncing
Contacting the box wall
A custom packaging assessment can identify the product’s strong and vulnerable areas.
Protect Protruding Components
Handles, connectors, switches, corners and other protruding parts may be damaged when the product shifts.
These parts should not be used as the main support points.
Protective packaging may include:
Clearance spaces
Custom cut-outs
Protective caps
U-profiles
Edge profiles
Honeycomb supports
Suspension structures
Rigid frames
Pressure should be directed toward stronger sections of the product.
Secure Accessories and Spare Parts Separately
Small accessories can move freely inside a box and damage the main product.
Examples include:
Screws
Tools
Cables
Remote controls
Brackets
Manuals
Spare components
Fasteners
Accessories should be placed in:
Separate compartments
Small inner boxes
Sealed bags
Document pockets
Custom trays
Fixed sleeves
They should not be placed loosely on top of or underneath the main product.
Consider Moisture and Humidity
Moisture can weaken paper-based boxes and internal packaging materials.
When internal supports lose strength, the product may become loose and begin shifting.
Moisture may come from:
High warehouse humidity
Container condensation
Wet floors
Rain exposure
Temperature changes
Long transportation periods
Wet pallets
Packaging should be stored in a clean and dry environment before use.
The expected transportation conditions should be considered when selecting paperboard, honeycomb components and other internal supports.
Moisture-resistant options may be required for certain applications.
Avoid Reusing Damaged Boxes
Previously used boxes may have:
Crushed corners
Weakened folds
Torn flaps
Moisture damage
Reduced compression strength
Punctures
Deformed walls
These weaknesses may allow the box to change shape during transportation.
As the box deforms, space may develop around the product and increase movement.
Inspect every box before use.
Do not reuse a box when its strength and condition are uncertain.
Prepare Clear Packing Instructions
A good packaging design may fail when employees assemble it incorrectly.
Packing instructions should explain:
Correct box size
Product orientation
Insert position
Divider position
Number of components
Layer-pad arrangement
Required top protection
Closure method
Tape position
Strapping requirements
Final inspection steps
Photographs or diagrams can help employees follow the correct process.
The packaging should be assembled consistently for every shipment.
Train Packing Employees
Packing employees should understand why each packaging component is required.
Training may include:
Correct product orientation
How to install inserts
How to position dividers
How to check product movement
How to seal the box
How to identify damaged packaging
How to follow packing specifications
How to report packaging problems
Employees should not remove internal components simply because the box appears difficult to close.
A difficult assembly may indicate that the product, insert or box is incorrectly positioned.
Perform a Movement Check
Before sealing the package, check whether the product moves.
A basic manual check may involve gently moving the box in different directions.
Listen and feel for:
Sliding
Rolling
Impact sounds
Loose accessories
Vertical movement
Divider movement
Insert movement
This basic check does not replace professional testing, but it may identify obvious packing errors before dispatch.
Heavy packages should not be lifted or shaken manually when doing so creates a safety risk.
Test the Complete Packaged Product
Packaging performance depends on the interaction between the product, internal supports, box, closures and handling process.
ISTA states that its test procedures are intended for a specific complete packaged-product system rather than approving an individual packaging material by itself.
Testing may include:
Vibration testing
Drop testing
Impact testing
Compression testing
Stacking evaluation
Handling trials
Incline-impact testing
Rotational-edge testing
Moisture conditioning
Forklift handling trials
The selected test should reflect the actual distribution environment.
A package used for courier delivery may experience different risks from a palletised industrial shipment.
Retest Packaging After Changes
Packaging should be reviewed when there is a change to:
Product dimensions
Product weight
Product shape
Centre of gravity
Box dimensions
Box material
Internal packaging
Dividers
Supports
Closure method
Pallet type
Transportation route
Distribution method
ISTA advises repeating packaged-product testing when changes to the product, packaging or distribution process may affect performance.
A small product change may create additional space or change the load distribution inside the box.
Existing packaging should not automatically be assumed to remain suitable.
Conduct a Trial Shipment
A trial shipment helps evaluate the packaging under actual operating conditions.
Record:
Product condition before packing
Box and insert specifications
Packing process
Transportation route
Handling method
Journey duration
Package condition upon arrival
Product position upon arrival
Visible movement
Product damage
Customer feedback
Take photographs before sealing and after opening.
The results can be used to improve the internal packaging design before full implementation.
Solutions for Different Product Types
Electronics
Electronics may require:
Custom inserts
Product separation
Surface protection
Accessory compartments
Controlled cushioning
Moisture consideration
Protection for connectors and screens
The product should remain fixed without placing pressure on sensitive areas.
Automotive Components
Automotive parts may have irregular shapes, sharp edges or concentrated weight.
Suitable packaging may include:
Honeycomb supports
Protective profiles
Custom frames
Layer pads
Dividers
Reinforced bases
Multiple support points
Oil or moisture protection may also be necessary for selected components.
Furniture Components
Furniture parts may require protection against:
Scratches
Edge damage
Corner damage
Surface contact
Movement
Protective profiles, dividers, wrapping and custom supports can help keep the components separated.
Metal Products
Metal products may be heavy and have sharp edges.
They may require:
Strong internal supports
Reinforced bases
Edge protection
Surface separation
Moisture protection
Secure weight distribution
Loose cushioning should not be relied upon for heavy metal components.
Food and Beverage Products
Packaged food and beverage products may require:
Dividers
Layer pads
Bottle separation
Carton reinforcement
Moisture consideration
Stable product orientation
The packaging materials should also meet the relevant hygiene and product requirements.
Household Appliances
Large appliances may require:
Honeycomb panels
Edgeboard
Top and bottom supports
Corner protection
Product-specific frames
Base reinforcement
Movement should be controlled without applying pressure to doors, controls or cosmetic surfaces.
Industrial Components
Industrial products may require custom packaging based on:
Product weight
Support points
Centre of gravity
Fragile sections
Lifting method
Transportation route
Generic void fill may not provide sufficient protection for heavy or specialised components.
Common Mistakes That Allow Products to Shift
Using a box that is too large
Adding random loose filling material
Failing to secure heavy products
Using dividers that are too loose
Leaving excessive headspace
Ignoring vertical movement
Using weak internal supports
Placing accessories loosely in the box
Using damaged cartons
Ignoring product weight distribution
Using the wrong product orientation
Failing to protect protruding components
Using packaging that weakens in humidity
Changing the product without updating the packaging
Skipping packaging tests
Using the same packaging for different product weights
Focusing only on the outer box
Ignoring customer handling conditions
Avoiding these mistakes can improve product protection and packaging consistency.
Packaging Checklist
Before closing the box, confirm that:
The correct box size is being used
The box is undamaged
The product orientation is correct
The product is supported at suitable points
The weight is evenly distributed
The inserts are correctly installed
Dividers fit securely
Multiple products cannot contact each other
Accessories are stored separately
Fragile components are protected
Empty space is controlled
Vertical movement is controlled
The base supports the product weight
Top protection is correctly positioned
The product does not move during a safe manual check
The box is correctly sealed
Labels and handling instructions are visible
The package has been tested for the intended journey
Frequently Asked Questions
Why do products shift inside boxes?
Products usually shift because the box is too large, internal support is insufficient, empty space is excessive or the packaging does not match the product’s shape and weight.
How can I stop a product from moving inside a box?
Use a correctly sized box together with custom inserts, dividers, supports, layer pads or suitable cushioning that holds the product securely in every direction.
What is the best material for filling empty space?
The best material depends on the product’s weight, fragility and transportation conditions. Options may include honeycomb board, corrugated inserts, paper-based cushioning, dividers and custom support structures.
Should there be any empty space inside a shipping box?
Some clearance may be required for protective packaging, but there should not be enough uncontrolled space for the product to slide, roll, bounce or strike the box walls.
Can honeycomb board prevent product movement?
Honeycomb board can be converted into supports, dividers, frames, panels and inserts that help hold products in position. The correct thickness and design depend on the application.
Can edgeboard be used inside a box?
Yes. Edgeboard can be used inside boxes to reinforce corners, support stacking strength, protect product edges or form part of an internal support system.
How do dividers prevent shipping damage?
Dividers create individual compartments that keep products separated and reduce product-to-product contact during handling and transportation.
Is loose void fill suitable for heavy products?
Loose void fill is generally not sufficient as the main restraint for heavy products. Heavy products usually require stronger custom supports, reinforced bases or internal frames.
How can I prevent products from moving vertically?
Use top pads, fitted inserts, internal frames or suitable cushioning to control the space above the product. The material should hold the product without excessive compression.
Does a stronger box prevent product movement?
A stronger box helps maintain the package shape, but internal packaging is still required to hold the product securely.
Should each product be wrapped individually?
Individual wrapping may protect surfaces, but it does not necessarily prevent movement. Wrapped products should still be separated and secured using suitable internal supports.
How can I secure multiple products in one box?
Use dividers, individual compartments, layer pads, sleeves or custom inserts to prevent the products from contacting one another.
Should packaging be tested before shipping?
Yes. The complete packaged product should be tested according to the expected handling, storage and transportation conditions.
When should packaging be retested?
Packaging should be reviewed and retested when changes are made to the product, box, internal packaging, closure method or distribution process.
How can I check whether a product is secure?
Before sealing the box, perform a safe movement check and confirm that the product, inserts and accessories do not slide, roll, bounce or move out of position.
Why Choose Eltete for Internal Protective Packaging?
Eltete provides paper-based transport packaging solutions that can help secure, separate and protect products during storage and transportation.
Available solutions may include:
Honeycomb board
Edgeboard
Protective profiles
Paper pallets
Pallet runners
Slip sheets
Custom transport boxes
Internal packaging components
Eltete’s transport-packaging range includes products that can be used together as part of a complete packaging system for stabilisation, unitisation and product protection.
A packaging assessment can consider:
Product dimensions
Product weight
Product shape
Fragile areas
Support points
Internal empty space
Transportation method
Handling conditions
Storage environment
Current damage problems
The internal packaging can then be designed according to the product and supply-chain requirements.
Conclusion
Preventing products from shifting inside boxes requires more than adding extra filling material.
The packaging should be designed to hold the product securely while protecting it from impact, vibration, compression and repeated handling.
Businesses should focus on:
Using the correct box size
Reducing unnecessary empty space
Using fitted inserts
Separating multiple products
Supporting heavy components
Controlling movement in every direction
Distributing weight evenly
Protecting fragile areas
Using strong outer packaging
Following consistent packing instructions
Testing the complete packaged product
Solutions such as honeycomb board, edgeboard, protective profiles, dividers and custom inserts can help keep products in the correct position.
The correct solution depends on the product’s weight, dimensions, shape, fragility and transportation environment.
Contact Eltete Malaysia
Are your products moving or becoming damaged inside their boxes during transportation?
Eltete Malaysia can assess your product, current packaging, internal empty space and handling requirements.
Contact Eltete Malaysia to discuss customised paper-based internal packaging and transport packaging solutions or request a quotation.
