Packaging has several jobs
Packaging is often thought of as just a box. In logistics it does several jobs at once: it protects goods from damage and the weather, groups items so they can be handled efficiently, carries information through labels, and sometimes serves as the retail presentation. Different layers of packaging take on different parts of these jobs.
The three layers
Packaging is commonly described in three levels.
Primary packaging is in direct contact with the product. A bottle, a blister pack, a pouch, or a retail carton are examples. It holds and protects the product and often carries the brand and legal information. For some goods, it also protects against air, light or moisture, which affects shelf life.
Secondary packaging groups primary packages together. A case holding twelve bottles, or a shipping carton holding several retail boxes, are examples. It makes goods easier to count, stack and handle.
Tertiary packaging supports bulk movement. This includes pallets, stretch wrap, straps, corner boards and large crates, which make a load that can be moved by forklift and carried by a truck or container. The basics of this layer are described under pallets and unit loads.
For parcels shipped to individual customers, the layers often collapse: a single outer carton may serve as secondary and tertiary packaging, with the product’s own box inside it.
Key materials
- Corrugated cardboard. Light, cheap and widely used. Strength depends on the thickness, the number of layers and the quality of the paper. Moisture weakens it substantially.
- Plastic films and bags. Used for wrapping, protection from moisture and tamper resistance.
- Rigid plastic and metal containers. Used where more strength or a seal is needed.
- Wood. Crates and pallets for heavy or awkward goods. Wood used in international shipping is often subject to treatment rules to prevent the spread of pests, and requirements vary by country.
- Cushioning materials. Foam, molded pulp, paper, air-filled film and corrugated inserts absorb shocks.
Cushioning and void fill
Two related jobs are often confused. Cushioning absorbs shock so that a drop or bump does not transmit full force to the product. Void fill occupies empty space so the product cannot move around inside the box. An item can be cushioned but still rattle if there is too much space, and it can be tightly filled but unprotected from impact.
A common approach is to keep the product away from the walls of the box, with a layer of cushioning on every side, so that an impact on a corner or edge does not reach the product directly. Fragile items typically need more space and more cushioning than robust ones, and heavy items need packaging that can bear their weight without bursting.
Closures
A strong box with a weak seal fails at the seal. Tape, adhesive, straps and staples are the usual closing methods. Tape should be suited to the box surface and applied in a way that covers the seams. Poorly applied tape is a common cause of boxes opening in transit, with resulting loss or theft.
Matching the packaging to the journey
The right packaging depends on factors that vary by shipment.
- Product. Weight, fragility, shape, value and sensitivity to moisture, temperature or static.
- Mode. Ocean shipping involves long durations and humidity; rail freight involves vibration and coupling shocks; parcel networks involve many automated and manual handlings, including drops and stacking.
- Number of handlings. Each transfer is a chance for damage.
- Stacking. Boxes at the bottom of a stack must carry the weight above them for the whole trip.
- Climate. Heat, cold and humidity can affect both product and packaging. Products needing controlled temperatures follow the principles of the cold chain.
- Regulations. Some goods, notably dangerous goods, must be packed in approved packaging with required markings; see hazardous materials.
Testing
Packaging can be tested before use. Drop tests, vibration tests, compression tests, and simulations of transport conditions are common ways to find weaknesses. Several organizations publish test procedures. For smaller businesses, simple trials, such as packing a sample and sending it on a real route, offer useful information at low cost.
The cost side
Better packaging costs more, but so do damaged goods, returns and replacements. The cost is not only the material: packing time, storage space for packaging, and the weight and size of the finished package all affect the final bill. Carriers often price by weight or by volume, so oversize packaging adds cost. The relationship between box size and cost is covered in right-sized packaging.
Packaging and the planet
Packaging is highly visible waste, so it features in many sustainability discussions. Over-packaging wastes material and space, while under-packaging leads to damaged goods, which can be a bigger waste. Choosing recyclable or reusable materials, reducing weight and avoiding oversized boxes are common steps. The goal is the least packaging that still reliably protects the product.