packaging home / Playbook
Logistics / practical steps
Choose packaging through evidence
A repeatable packing brief for comparing protection, handling, parcel size and material use.
STEP 01
Describe the failure you need to prevent
Record the product’s size, weight, fragile areas, surfaces and sensitivity to movement or leakage. Review actual damage reports. A scuffed surface, broken corner and crushed carton can require different changes even when all are reported as “damaged in transit”.
STEP 02
Specify a complete pack-out
List the outer container, internal supports, cushioning, closures and label position. Document how an operator assembles the pack. A strong box cannot compensate for an item moving freely inside it or a closure that opens during handling.
STEP 03
Compare measured alternatives
Pack a real sample with each candidate design. Measure the finished parcel, not the empty box, and record material quantities and packing time. Use the carrier’s own charging rules when estimating transport cost; do not assume every service uses the same volumetric divisor.
STEP 04
Pilot and review damage evidence
Use appropriate testing and a limited shipment pilot for the actual product and route. Keep photographs and batch identifiers. Review damage, returns and packing consistency together before changing the specification for all orders.
Choose the right next step
- Fragile product: prioritise restraint and protection of vulnerable areas.
- Low-density parcel: review dimensions without sacrificing required protection.
- High packing variation: simplify the work instruction and check representative operators.
Worked example
A seller tests two inserts for the same product. It records the finished dimensions, minutes to pack, material cost and damage outcomes. The smaller carton is adopted only after it meets the agreed protection criteria, rather than because it looks more efficient.