When a customer receives a damaged shipment, the first question is often:
“What happened during transport?”
But transport damage does not always happen while the truck or container is moving.
A product may pass through many different handling stages before it reaches the customer.
It may be packed at the factory, moved by forklift, stored in a warehouse, stacked, loaded into a truck, transferred into a container and unloaded again at the destination.
Damage can happen at any one of these stages.
Eltete Malaysia notes that export products may pass through production areas, factory warehouses, loading bays, trucks, shipping ports, containers, distribution centres and customer warehouses. Every handling point can introduce impact, movement or packaging damage.
Understanding where damage is likely to happen is the first step towards designing better transport packaging.
Packaging Damage Is Usually a Journey Problem
Packaging is sometimes designed around only one condition.
For example:
“How strong does the box need to be?”
That is important, but it is only one part of the problem.
The shipment may also need to survive:
– Forklift impact
– Repeated warehouse movement
– Stacking pressure
– Strapping pressure
– Vehicle vibration
– Sudden braking
– Container movement
– Contact with other pallet loads
– Loading and unloading
Eltete identifies impact, compression, strapping pressure, movement, vibration, moisture and unstable loads among the risks that should be considered when developing a transport packaging solution.
A stronger packaging design starts by asking:
Q – What will happen to this product between our factory and the customer?
Stage 1: Forklift Handling Forklift handling is one of the first areas manufacturers should review. Palletised products may be moved several times before they even leave the warehouse.
A forklift may:
– Pick up the pallet from production.
– Move it into storage.
– Move it to the loading area.
– Load it into a truck.
– Unload it again at another facility.
– Every movement creates an opportunity for impact.
Q – How Forklift Damage Happens ?
A – Forklift-related damage may occur when:
– The forks strike a carton.
– The pallet is approached at the wrong angle.
– The load is lifted unevenly.
– The pallet hits another pallet.
– A load is pushed against a wall.
– The pallet base is damaged.
– Boxes overhang the pallet.
– Eltete specifically identifies improper forklift handling and pallet overhang as possible causes of corner and packaging damage.
– The exposed corners of palletised goods are especially vulnerable.
– They may be the first part of the shipment to contact warehouse equipment or another load.
– Packaging Design Response
– The packaging should provide protection around areas most likely to receive impact. Eltete Edgeboard can be positioned along vertical pallet corners to protect exposed edges and support the shape of the load.
– The pallet itself should also match the product dimensions. Products that extend beyond the pallet footprint have less support underneath them and become more exposed to forklift impact.
– For suitable applications, the packaging design may therefore combine:
– Suitable pallet + aligned load + Edgeboard + wrapping or strapping
– The purpose is not to make forklift impact acceptable. Operators should still handle loads correctly.
– The packaging provides an additional level of protection when normal logistics handling creates unavoidable contact or movement.
– Stage 2: Movement Inside the Warehouse
– A shipment may travel a surprisingly long distance inside the facility before export.
– It may move between:
– Production
– Packing
– Quality inspection
– Temporary storage
– Finished-goods warehouse
– Loading bay
– Each movement may seem minor.
– But repeated movement can expose weaknesses in the packaging.
Q – What Can Happen?
– Cartons can begin shifting.
– Products may move inside boxes.
– Edge protection can move out of position.
– Stretch film can become damaged.
– Straps may loosen.
– The load may begin leaning.
– A pallet may remain upright while the products inside individual cartons move repeatedly.
– Eltete notes that product movement can result from empty space, weak internal support, incorrect packaging size, vibration and insufficient securing.
– Packaging Design Response
– Packaging should control movement at two levels.
– The first level is inside the package.
– The product should not have enough uncontrolled space to repeatedly hit the box walls.
Eltete Honeycomb Board can be used for internal applications such as:
– Cushioning
– Product separation
– Dividers
– Void filling
– Weight distribution
– Structural support
– It can be cut or shaped according to the product. The second level is the complete pallet load.
– Cartons should remain aligned and unitised using an appropriate combination of Edgeboard, stretch film and strapping.
– The internal and external packaging must work together.
– Stage 3: Warehouse Stacking
– Storage introduces a different type of risk. The pallet may not be moving at all.
– Instead, the problem comes from pressure. When products or pallet loads are stacked, the packaging underneath must carry the weight above it.
Q – How Stacking Damage Happens ?
Poor stacking can cause:
– Crushed cartons
– Collapsed corners
– Leaning loads
– Deformed packages
– Damaged products
– Loss of load stability
– Eltete explains that package corners carry part of the vertical pressure when products are stacked. If the packaging is weak or weight is distributed unevenly, these corners can become crushed.
The risk may increase when:
– A weak carton is placed at the bottom.
– Heavy products are positioned above lighter loads.
– The pallet is uneven.
– Weight is concentrated in a small area.
– The stack remains in storage for a long period.
– Humidity weakens paper-based packaging.
– Packaging Design Response
– Stacking strength needs to be considered from the beginning.
– Manufacturers should evaluate:
– Product weight
– Carton strength
– Stacking height
– Storage duration
– Weight distribution
– Pallet support
– Warehouse conditions
– Eltete Edgeboard can provide additional vertical corner support and contribute to stacking strength when selected correctly for the application.
– Honeycomb Board may also be used where the package needs additional structural support or weight spreading.
The key principle is:
– Do not ask only whether the carton can hold the product. Ask whether the complete package can support the conditions above and around it.
– Stage 4: Truck Transport
– Once the shipment enters a truck, the risk changes again. The load now experiences continuous movement.
– Even when the truck is driven normally, the cargo may experience:
– Acceleration
– Braking
– Turning
– Road vibration
– Uneven road surfaces
– Repeated small impacts
– Eltete identifies vehicle vibration, sudden braking and sharp turns as potential causes of load movement.
– Why Small Movements Matter
– A pallet does not need to fall over completely to suffer transport damage.
– Small repeated movements may be enough.
– A carton can rub against another carton.
– A product can repeatedly hit an internal surface.
– A pallet can move closer to another load.
– Strapping may shift position.
– Corners may experience repeated pressure.
– Over a long trip, these small movements can build into visible damage.
– Packaging Design Response
– The load needs to be stable both internally and externally.
– Inside the package, products should be supported so they cannot move freely.
– On the pallet, cartons should be aligned and unitised.
Eltete’s transport packaging approach may use components such as:
– Edgeboard
– Honeycomb Board
– Paper Pallet
– Stretch film
– Plastic or steel strapping
– These components can be selected according to the product and handling conditions.
– But there is another level to consider.
– The complete pallet can still move inside the truck.
– That requires cargo-level securing.
– Stage 5: Movement Between Pallets Inside the Truck or Container
– A perfectly packed pallet can still become damaged if the entire pallet moves.
– Imagine two stable pallet loads inside a container. Both are properly wrapped. Both have Edgeboard. The cartons are secure. But there is a large empty gap between the pallets. When the vehicle brakes or turns, one complete pallet may shift into the other. The problem is no longer internal product protection. It is cargo movement.
– Eltete makes this distinction clearly: Honeycomb Board can help manage empty space around the product, while Dunnage Bags are used for larger gaps between complete cargo units inside trucks, containers, trains or ships.
– Packaging Design Response
– Once complete loads are inside the transport unit, check the spaces between them. Eltete Dunnage Bags are inflatable cargo-securing cushions designed to occupy selected gaps between cargo units. Once positioned and inflated, they help cushion the loads and restrict movement during transportation.
– A complete arrangement could therefore be:
Product
↓
Internal Honeycomb protection
↓
Outer carton
↓
Pallet + Edgeboard
↓
Wrapping / strapping
↓
Dunnage Bags between complete cargo units
Each component solves a different level of movement.
– Stage 6: Container Loading
– Container loading is another high-risk point. Products are being moved from one environment into another. Forklifts or other handling equipment may need to operate in limited space. Pallets may come into contact with:
– Container doors
– Container walls
– Other cargo
– Loading equipment
– Nearby pallets
– Common Loading Problems
Damage may occur because:
– A pallet enters the container at the wrong angle.
– A carton strikes the door frame.
– The load is pushed too closely against another pallet.
– The cargo is not arranged to distribute weight correctly.
– Large gaps remain between cargo units.
– The product has insufficient corner protection.
– Eltete notes that corner damage can happen during container loading and that exposed edges may experience impact or compression during handling.
– Packaging Design Response
– Container loading should be considered before the packaging is finalised.
Ask:
Q – How will the load enter the container?
Q – How much clearance is available?
Q – Can the pallet be approached correctly?
Q – Where are the most exposed corners?
Q – Will the load be stacked?
Q – Where will gaps remain?
Q – How will those gaps be controlled?
This may affect the required:
– Pallet dimensions
– Outer package dimensions
– Edgeboard specification
– Internal support
– Wrapping system
– Dunnage Bag arrangement
– Packaging design should match the physical logistics environment rather than being designed in isolation.
Stage 7: Container Transport
– Once the container is closed, the shipment is no longer visible. But the packaging still has work to do. During transportation, the container and cargo may experience repeated movement. For sea freight, the journey may also be long. Cargo can shift if the complete load is not properly secured.
– Eltete states that empty spaces between palletised loads can allow products to move when the transport unit accelerates, brakes, turns or experiences movement in transit.
Packaging Design Response
Product protection at this stage should be considered at three levels.
– Level 1 — Product
– Can the product move inside its own package? Honeycomb Board, dividers, supports and other internal components may help control this.
– Level 2 — Palletised Load
– Can individual cartons shift or lose alignment? Edgeboard, wrapping and strapping can help unitise and stabilise the load.
– Level 3 — Cargo Unit
– Can the complete pallet move within the container? Dunnage Bags or other suitable cargo-securing methods may be required. Looking at these three levels separately makes it easier to identify where the packaging design is failing.
Stage 8: Unloading
– The shipment has reached its destination. But the damage risk is not over. Unloading often means another round of forklift handling. The receiver may also use different equipment, warehouse procedures or handling methods from the sender.
– How Damage Happens During Unloading
Common risks include:
– Forklift impact
– Incorrect fork positioning
– Pulling or pushing loads
– Contact with other pallets
– Dropping or lowering too quickly
– Damaged pallets
– Unstable loads shifting when released
– Packaging that was already weakened during transportation may also fail at this final stage. A crushed corner that survived the journey may collapse when the pallet is lifted.
– A loose load may shift as soon as it is moved.
– Packaging Design Response
– The packaging must survive the entire logistics journey, not only the outbound warehouse. Eltete recommends considering the product, handling method and destination when selecting transport packaging components. This means exporters should understand receiving-side conditions too.
Ask the customer:
Q – What forklift equipment do you use?
Q – How is the product unloaded?
Q – Will the pallet be moved again?
Q – Will the load be stored or unpacked immediately?
Q – Will it be stacked?
– These details may change the packaging requirement.
Q – Where Is Your Damage Actually Happening?
A – If damage keeps happening, avoid immediately adding more packaging.
– First, identify where in the journey the failure appears to begin. Damage Mainly on Exposed Corners
Possible causes:
– Forklift contact
– Pallet overhang
– Strapping pressure
– Contact with nearby loads
Packaging areas to review:
– Edgeboard
– Pallet size
– Load alignment
– Strapping position
– Crushed Bottom Cartons
Possible causes:
– Excess stacking pressure
– Poor weight distribution
– Weak carton specification
– Insufficient pallet support
Packaging areas to review:
– Carton strength
– Pallet design
– Honeycomb support
– Weight distribution
– Stacking arrangement
– Products Damaged but Outer Box Looks Fine
Possible causes:
– Internal movement
– Excess empty space
– Poor product support
– Vibration
Packaging areas to review:
– Honeycomb Board
– Dividers
– Supports
– Void filling
– Correct box dimensions
– Entire Pallet Has Shifted
Possible causes:
– Insufficient wrapping
– Poor strapping
– Incorrect stacking
– High centre of gravity
Packaging areas to review:
– Load alignment
– Edgeboard
– Stretch film
– Strapping
– Pallet configuration
– Pallets Collide Inside Container
Possible causes:
– Uncontrolled gaps
– Cargo movement
– Insufficient securing
Packaging area to review:
– Dunnage Bags or another suitable cargo-securing method
– Do Not Confuse Product Movement with Cargo Movement
– This distinction is especially important.
A manufacturer may say:
“The goods moved during shipping.”
Q – But what actually moved?
A – The Product Moved Inside the Box
This is mainly an internal packaging problem.
Review:
– Honeycomb Board
– Supports
– Dividers
– Void filling
– Packaging dimensions
– Cartons Moved on the Pallet
– This is mainly a pallet stability problem.
Review:
– Stacking
– Edgeboard
– Strapping
– Stretch film
– Pallet dimensions
– The Complete Pallet Moved in the Container
– This is mainly a cargo securing problem.
Review:
– Container loading arrangement
– Gaps between loads
– Dunnage Bags
– Suitable cargo restraint
– Eltete describes Honeycomb Board and Dunnage Bags as solutions for different types of voids: Honeycomb around products and Dunnage Bags between complete cargo units. Identifying the correct level prevents companies from trying to solve the wrong problem.
– Packaging Should Be Designed Around the Weakest Stage
– A shipment may survive six parts of the logistics journey perfectly and fail at the seventh.
For example:
– The box is strong enough.
– The pallet is stable.
– The load survives truck transport.
– But the exposed corner repeatedly gets hit during forklift unloading.
– In that case, making the complete box heavier may not be the best answer.
– The real requirement may be targeted corner protection.
– Eltete’s Transport Packaging Solutions concept follows this type of approach.
– Different components can perform different functions, including:
1 – Edgeboard
– Corner protection, stabilisation and strapping protection.
2 – Honeycomb Board
– Cushioning, separation, structural support and internal void filling.
3 – Paper Pallet or PallRun®
– Load support and handling.
4 – U-Profile and other protective profiles
Protection for selected vulnerable product areas.
5 – Stretch film and strapping
Load containment and unitisation.
6 – Dunnage Bags
Control of cargo movement between complete loads.
– Eltete states that the exact components should be selected according to the individual application rather than using unnecessary packaging material. Record Damage Before Changing the Packaging Manufacturers experiencing repeated transport damage should collect information before redesigning the packaging.
– Take photographs.
– Record where the damage appears.
– Check whether the same area is affected repeatedly.
Useful information includes:
– Damage location
– Product affected
– Carton condition
– Pallet condition
– Edgeboard position
– Strapping location
– Wrapping condition
– Transport route
– Handling points
– Shipment dimensions
– Shipment weight
Eltete specifically recommends sharing photographs and information about the existing packaging and actual damage when evaluating a new transport packaging solution.
This makes it easier to identify whether the problem comes from impact, compression, movement, strapping pressure or another cause.
A Simple Transport Damage Journey Check
Before approving an export packaging design, follow the shipment mentally from beginning to end.
Forklift Handling
Q – Can exposed areas survive normal handling?
A – Warehouse Movement
Q – Can the product remain stable after repeated movement?
A – Stacking
Q – Can the lower packaging support the load above?
A – Truck Transport
Q – Can the product handle vibration, braking and turning?
A – Container Loading
Q – Can the package enter without exposed areas being damaged?
A – Container Transport
Q – Can the complete cargo remain secure throughout the journey?
A – Unloading
Q – Will the packaging still be stable when handled at the destination?
A – If the answer to one of these questions is unclear, that stage should be examined more closely.
Better Packaging Begins by Understanding the Journey
Transport damage rarely happens because a shipment simply travelled from Malaysia to another country.
Damage happens because of specific forces at specific stages.
– A fork strikes a corner.
– A carton carries too much stacking pressure.
– A product moves inside an oversized box.
– A strap concentrates pressure on one edge.
– A pallet shifts during braking.
– Two cargo units collide inside a container.
– Each problem requires a different packaging response.
That is why effective transport packaging should be designed around the complete journey, not only the product sitting safely inside the factory.
Eltete Malaysia’s Transport Packaging Solutions concept allows products such as Edgeboard, Honeycomb Board, Paper Pallets, PallRun®, protective profiles and Dunnage Bags to be combined according to the actual protection, handling and transportation requirements.
Find where the damage happens first. Then design the protection around that risk.
If your shipments repeatedly arrive with crushed corners, unstable loads, internal product movement or other transport damage, Eltete Malaysia can evaluate the existing packaging configuration and identify the areas that may require improved support or protection.
Learn more at www.eltete.com.my
