A shipment may look secure when it leaves the warehouse, but that does not always mean the packaging is ready for the complete transportation journey.
Products may be handled by forklifts, stacked in warehouses, loaded into containers, transported over long distances and moved several times before reaching the customer. Each stage can place different pressure on the packaging. For manufacturers and exporters, a simple packaging audit before shipment can help identify weak areas before they become transport problems.
The objective is not simply to add more packaging. The objective is to make sure the right packaging components are protecting the right areas of the load.
Q – What Is a Pallet Packaging Audit?
A – A pallet packaging audit is a systematic review of a packaged load before it is transported.
Instead of checking only whether the product is wrapped or strapped, the audit looks at the complete packaging system.
– This may include:
– Product arrangement
– Pallet or load base
– Carton condition
– Corner protection
– Strapping
– Stretch wrapping
– Load height
– Weight distribution
– Stacking requirements
– Handling method
– Transportation environment
– The purpose is to identify areas where the load may move, deform or become damaged during handling and transportation. Eltete’s transport packaging approach similarly considers the product, handling method and shipment requirements when selecting packaging components rather than relying on one standard solution for every load.
1. Check the Product Arrangement
– Start with the products themselves. Look at how cartons, boxes, bags or individual products are positioned on the pallet.
Ask:
Q – Are the products aligned?
Q – Is the weight distributed evenly?
Q – Are there large gaps between products?
Q – Are any cartons extending beyond the pallet?
Q – Are heavy products positioned above weaker products?
– An uneven load can become difficult to stabilise even when large amounts of stretch film or strapping are added. The packaging system should begin with a stable product arrangement.
2. Inspect the Load Base
– The pallet or load base supports everything above it.
– Check whether:
Q – The load fits the dimensions of the base
Q – The base is damaged
Q – The weight is distributed correctly
Q – Forklift access is suitable
Q – The load remains stable during handling
– Different products may require different load platforms. Eltete’s transport packaging range includes paper based pallet solutions and Slip Sheets that can be selected according to the product and handling requirements.
– Do not assume that the same pallet configuration will work for every shipment.
3. Look for Vulnerable Corners and Edges
– Corners often receive pressure from handling, stacking, wrapping and strapping. Inspect the full height of the load.
Look for:
– Crushed carton corners
– Bent edges
– Damaged packaging
– Exposed product edges
– Areas receiving direct strap pressure
– If vulnerable corners are left unprotected, damage can occur even when the rest of the load appears secure. Edgeboard is one option for reinforcing exposed edges, distributing strapping pressure and helping support pallet load stability. The correct profile should be selected according to the actual shipment rather than simply choosing based on appearance or thickness.
4. Check the Strapping
– Strapping should secure the load without damaging the packaging underneath it. Inspect every strap.
Q – Check whether the straps are:
1 – Too loose
– Loose strapping may not keep products securely together.
2 – Too tight
– Excessive tension can deform cartons and damage vulnerable corners.
3 – Placed in unsupported areas
– A strap positioned over a weak section of a carton may create concentrated pressure.
4 – Touching sharp edges
– Sharp product edges may damage the strap.
5 – Properly protected
– Corner or edge protection may be required where straps meet vulnerable packaging. Adding more straps does not automatically make a shipment safer. The complete packaging configuration needs to be considered. Eltete’s existing guidance also notes that excessive strapping can create additional pressure points instead of solving the underlying stability problem.
5. Review the Stretch Wrapping
– Stretch film can help contain a palletised load, but it should not be expected to solve every stability problem.
Check:
– Whether the film covers the required area
– Whether the load remains aligned underneath it
– Whether corners are deforming
– Whether products can still move inside the wrapped unit
– Whether the wrapping is too loose or unnecessarily excessive
– If cartons are already leaning before wrapping, additional layers of stretch film may only hide the problem. The cause of instability should be identified first.
6. Check the Top and Side Surfaces
– Packaging audits should not only focus on the four corners.
Inspect:
1 – Top surfaces
– Can another load be stacked above?
– Is additional protection required?
– Could straps or handling pressure damage the surface?
2 – Side surfaces
– Are products exposed ?
– Could another pallet make contact with them ?
– Could movement inside a container cause surface damage ?
– Products with large flat surfaces may require different protection from products that primarily need edge protection.
– Honeycomb Board and other protective paper based materials can be used as part of suitable packaging systems where surface protection or structural support is required.
7. Consider the Handling Method
– Think beyond the warehouse.
– How will the shipment actually move?
– It may be handled by:
– Hand pallet trucks
– Forklifts
– Push pull equipment
– Warehouse racking
– Container loading equipment
– Distribution centres
– Packaging that performs well while stationary may behave differently when lifted, accelerated, stopped or transferred. A useful audit therefore includes a review of the actual handling process. For Slip Sheet applications, for example, load arrangement, pull tab accessibility and push pull handling requirements need to be considered as part of the complete system.
8. Consider the Transportation Environment
– Ask where the shipment is going. A local delivery and a long distance export shipment may experience very different conditions.
Consider:
1 – Journey duration
– Longer journeys create more opportunities for handling and movement.
2 – Humidity
– Changes in storage and transportation environments may affect packaging performance.
3 – Stacking
– Products may remain stacked for long periods.
4 – Container movement
– Loads can experience movement during road and sea transportation.
5 – Repeated handling
– Export shipments may pass through several logistics stages before reaching their destination. Packaging should therefore be evaluated based on the entire distribution journey, not only the condition inside the factory.
9. Inspect the Load From Every Side
– A simple but useful final check is to walk around the complete shipment.
– Inspect it from:
– Front
– Back
– Left
– Right
– Top
– Look for:
– Leaning
– Bulging cartons
– Crushed corners
– Loose straps
– Damaged wrapping
– Product overhang
– Uneven load height
– Exposed edges
Unprotected surfaces
– Taking photographs before dispatch can also help create a record of the packaging condition.
10. Test Before Large Scale Implementation
– When a packaging configuration changes, it should be evaluated before being applied to a large number of shipments.
– Testing may include:
– Handling trials
– Forklift movement
– Strapping evaluation
– Compression testing
– Stacking trials
– Transport trials
– Inspection after delivery
– The objective is to understand how the complete packaging system performs under realistic conditions. A solution that works for one product may not automatically be suitable for another product with different dimensions, weight or handling requirements.
– More Packaging Is Not Always Better One of the most important results of a packaging audit may be discovering that the shipment does not need more packaging.
– It may need better packaging design. Adding another layer of film, another strap or another protective component without understanding the original problem may increase material use and packing time without correcting the actual weakness.
– A better approach is:
– Identify the risk → locate the weak point → select the appropriate protection → test the complete system.
– This creates a more controlled transport packaging process.
Q – When Should You Review Your Packaging ?
A – A packaging audit should be considered when:
– Shipping a new product
– Changing product dimensions
– Increasing shipment weight
– Changing pallets
– Changing strapping
– Changing logistics providers
– Exporting to a new market
– Experiencing repeated transport damage
– Receiving customer complaints
– Changing warehouse processes
– Moving from pallets to Slip Sheets
– Changing container configurations
– Even an existing packaging system should be reviewed when transportation conditions change.
Frequently Asked Questions
Q – What is a packaging audit?
A – A packaging audit is a review of the complete packaging configuration to identify possible weaknesses before handling, storage or transportation.
Q – What should be checked before exporting a pallet?
A – Check the product arrangement, load base, corner protection, strapping, wrapping, weight distribution, stacking requirements, handling method and transportation conditions.
Q – Does adding more stretch film improve pallet stability?
A – Not necessarily. Stretch film can help contain a load, but poor stacking, weak cartons or unsuitable load configuration should be corrected rather than simply covered with additional film.
Q – Why do pallet corners become damaged?
A – Damage may occur because of impacts, concentrated strapping pressure, insufficient support, unsuitable packaging or movement during transportation. Edge protection can be used where appropriate to help protect vulnerable areas.
Q – Can Edgeboard improve pallet stability?
A – Edgeboard can contribute to palletisation, stabilisation, unitisation, corner protection and stacking support when correctly selected and combined with the rest of the packaging system.
Q – Should every pallet use the same packaging configuration?
A – No. Product dimensions, weight, handling, stacking and transportation requirements can differ significantly. Packaging should be selected according to the application.
– Audit Before You Ship
– Transport packaging should not only look secure. It should be designed to remain suitable throughout handling, storage and transportation.
– A simple pre shipment audit can help manufacturers identify weak corners, unsuitable strapping, unstable loads and other potential packaging issues before the shipment leaves the facility. Eltete Malaysia provides transport packaging solutions including Edgeboard, Paper Pallets, Slip Sheets, Honeycomb Board and other paper based protective packaging products for industrial and export applications.
Q – Need to Review Your Current Transport Packaging ?
A – Share your product dimensions, weight, handling method and shipment requirements with Eltete Malaysia.
Visit www.eltete.com.my
