Poor packaging is one of the leading causes of cargo damage during freight — and damaged goods mean insurance claims, replacement costs, delays, and unhappy customers. Whether you're shipping a single pallet domestically or a full container overseas, how you package your goods can make the difference between them arriving in perfect condition or being written off. Here are five essential tips every shipper should follow.
Why Packaging Matters in Freight
During a typical international freight journey, cargo can be loaded and unloaded multiple times — at the origin warehouse, the export port, the vessel, the destination port, and the final delivery point. At each touchpoint, goods are subject to mechanical handling, stacking, vibration, temperature and humidity changes, and the potential for moisture ingress. Packaging that is adequate for a short road journey may be wholly insufficient for a six-week sea voyage.
Insurance policies also frequently contain packaging exclusions — if goods are damaged due to inadequate packaging, your claim may be denied. Taking the time to pack properly is not just good practice; it is a commercial necessity.
Tip 1 — Choose the Right Box or Crate
Not all cartons are equal. Double-wall corrugated cardboard boxes offer significantly more strength and crush resistance than single-wall alternatives and should be used for heavier or more fragile items. For very heavy, awkward, or high-value goods, a wooden crate or custom-built timber frame provides superior protection and is better suited to forklift handling.
Always choose a box that is the right size for your product. Oversized boxes with insufficient internal cushioning allow goods to move around in transit, leading to impact damage. The box should fit snugly around your product with adequate padding on all sides — there should be no empty space. If you are re-using boxes, inspect them carefully for any signs of previous damage, crush, or moisture, and replace them if there is any doubt about their structural integrity.
Tip 2 — Use Adequate Cushioning and Void Fill
Cushioning absorbs shocks and vibrations that occur throughout the freight journey. Bubble wrap, foam sheets, air pillows, and moulded polystyrene inserts are all effective options depending on the nature and fragility of your goods. For very fragile items, consider double-boxing — placing the item in an inner box surrounded by foam or bubble wrap, then placing that inner box in a larger outer carton with additional void fill.
Avoid using paper shredding or crumpled newspaper as primary cushioning for heavy items — these materials compress quickly under weight and provide minimal shock absorption. For heavier goods, closed-cell foam or custom moulded inserts provide far better performance. Ensure that goods cannot shift within the packaging when the carton is shaken — if you can hear or feel movement, add more cushioning.
Tip 3 — Secure Heavy Items at the Bottom
When packing mixed loads — whether in a carton, on a pallet, or inside a container — always place the heaviest items at the bottom. This applies at every level of packaging. Heavy items placed on top of lighter, more fragile goods will crush them, even if the outer packaging appears intact. Within a carton, heaviest items go at the base. On a pallet, heaviest boxes go on the bottom layers with lighter boxes stacked on top.
When palletising goods, ensure cartons are stacked column-style or brick-pattern and are tightly shrink-wrapped or strapped to prevent movement. Pallet wrap alone is often insufficient for sea freight — consider cross-strapping with plastic or steel banding for heavier loads. The pallet itself should be in good condition with no broken slats, as a failed pallet can cause the entire load to collapse during forklift handling.
Tip 4 — Waterproof Your Packaging
Moisture damage is a major cause of cargo claims, particularly for sea freight. Even sealed containers are not immune — temperature fluctuations during a voyage cause condensation inside containers (sometimes called "container rain"), and goods can be exposed to rain or humidity during loading and unloading at ports.
For moisture-sensitive goods such as electronics, textiles, food products, and paper goods, use moisture barrier bags or poly-lined cartons. Desiccant packs placed inside boxes and containers absorb excess moisture and are a low-cost investment against significant potential losses. For palletised goods, consider a waterproof pallet cover or shrink-wrap that extends beneath the base of the pallet. Any packaging that will be used in open storage at a port should be able to withstand at least brief exposure to rain.
Tip 5 — Label Clearly and Completely
Clear, correct labelling is essential for ensuring your goods reach the right destination and are handled appropriately throughout the supply chain. Every package in a shipment should be labelled on at least two sides with the following information:
- Shipper details: Full name, address, and contact number of the sender
- Consignee details: Full name, address, and contact number of the recipient
- Gross weight: The total weight of the package including packaging
- Dimensions: Length, width, and height in centimetres
- Carton number: e.g. "1 of 5", "2 of 5" for multi-carton shipments
- Handling instructions: "Fragile", "This Way Up", "Keep Dry", or "Do Not Stack" symbols and text where relevant — use internationally recognised ISO symbols for maximum clarity across language barriers
Labels should be printed clearly, not handwritten, and affixed securely using packing tape so they cannot peel off in humid or wet conditions. For international shipments, ensure all labelling complies with the regulations of the destination country — some countries have specific requirements for labelling language, safety symbols, or country-of-origin markings.
When in Doubt, Ask Your Freight Forwarder
If you are unsure whether your packaging is suitable for your intended freight method and destination, ask your freight forwarder before you ship. An experienced forwarder can advise on packaging standards for specific trade lanes, hazardous goods packaging requirements, and whether your goods would benefit from professional packing services.
At AusTalk, we work with our clients to ensure their cargo arrives safely and in compliance with all applicable regulations. Our team is happy to review your packaging arrangements and recommend improvements before your next shipment. Get in touch with us today.
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