Why packaging sometimes fails during deliveries
02/03/2026 by Fenton Richardson
Every year, millions of items leave warehouses in pristine condition, but arrive damaged due to poor packaging.
According to Oumar Fofana, writing for the website Packaging Gateway, damage in transit is a top persistent and costly problem in supply chains. However, there are straightforward solutions for this issue and ways to prevent packaging failures.
Often, packaging is designed for ideal conditions, such as being driven on short journeys on smooth roads. In real-world scenarios, there may be vibrations, temperature changes and parcels dropped when loading or unloading vehicles. Also, packages that are stacked too high can be subject to crush damage.
Even if an item is packed well, poor handling can cause damage. Good handling practices require quality training for warehouse operators. Repetitive drops, even from short heights, can cause damage. Operators need to be skilful in how they lift items from shelves to the picking trolley and onto the packing tables.
There is pressure to save on packaging costs by using cheap, poor-quality materials. This is false economy if this increases transit damage. For instance, changing from double-wall corrugated board to single board or using generic void fill rather than moulded inserts reduces protection.
Packaging should match the product and the journey it takes to reach its delivery destination. A packing person needs clear instructions on packing procedures, with specific instructions for every item that is packed.
If the true causes of transit damage are understood, the challenge can be addressed and items better protected. This saves money and improves customer satisfaction.
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