Packaging

✅ Why this step locks in structural protection before shipment

Packaging isn’t just a box—it’s your final defense against damage, delay, or delivery failure.

At this stage, you’re preparing your product for real-world handling: stacking, shipping, customs, and customer delivery. This is about protective packaging—the trays, inserts, seals, and cartons that keep your product safe and presentable during transport. Done right, it ensures every product arrives intact, compliant, and ready to delight.

📘 What you’ll define

  • Structural packaging layers for shipping and protection
  • Cartons, trays, wraps, seals, and materials that prevent impact or compression damage
  • Box strength, stackability, and logistics handling specs
  • Label, barcode, and document slots to pass customs and QA
  • Final layout that matches pick-and-pack or pallet systems

🛠️ Tools and methods

  • Packaging Bill of Materials (Pack BoM)

    List all items used in packaging: outer cartons, foam inserts, void fill, labels, bags, etc.

  • Shipping-Grade Drop and Crush Testing

    Simulate real handling conditions (e.g. ISO 2248, ISTA 1A/3A) to validate durability.

  • Stacking Load & Pallet Fit Tests

    Confirm packaging strength and size compatibility with warehouse or freight systems.

  • Exploded Layer Diagrams

    Visually map tray layouts, wrap folds, and sealing sequences for operators.

  • Label & Compliance Slot Planning

    Ensure all required documents (e.g. DoC, serial, barcode) are easily accessible and protected.

⚠️ Packaging pitfalls to avoid

  • Under-engineering for freight. Transit environments are rough—don't assume “looks fine” = “survives shipment”.
  • Mismatched dimensions. Boxes that don’t fit pallets, bins, or shelf spaces cost time and money.
  • Unclear carton labelling. Wrong or missing external labels can delay or reject shipments.
  • Packaging too late. Avoid last-minute fixes—plan structural packaging in parallel with final prototyping.

💡 From the warehouse floor

“A beautiful unit arrived crushed because we reused an inner box that wasn’t tested. Now we spec packaging strength with the same rigour as the product itself.”

– Fulfilment & QA Manager, Medical Devices Startup

💡 Run a pilot shipment to your own team first. Unbox it like a customer would—what survives? What fails?

🔗 Helpful links & resources

✍️ Quick self-check

  • Does every part of the product stay protected through stacking, impact, and vibration?
  • Are packaging layers clear, consistent, and scalable for assembly lines or 3PL?
  • Are all regulatory documents and identifiers properly placed and protected?
  • Have we validated the pack under real-world shipping, storage, and handling scenarios?

🎨 Visual concept (optional)

Illustration: A shipping carton exploded into layers—foam tray, product unit, sealed bag, lid, outer box. Arrows indicate packing sequence. On the table: a crushed test box marked “FAIL – compress at 30kg” and another labeled “PASS – 50kg stack”. A sticky note reads: “Add side label + doc pouch here”.

Visual shows how structural packaging integrates protection, process, and logistics—ensuring your product arrives ready to impress.
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