How to Reduce Shipping Damage: 10 Ways to Protect Products in Transit

Shipping damage is one of the most common challenges faced by businesses that send products through courier networks, pallet distribution systems and freight services.

Damaged goods can lead to costly replacements, returns, negative reviews and lost customers. Even when the product survives intact, damaged packaging can create a poor first impression and reduce customer confidence.

The good news is that most shipping damage can be prevented with the right packaging strategy.

In short: The best way to reduce shipping damage is to use the correct box strength, choose the right box size, prevent movement inside the box and select suitable protective packaging for your product, transit method and supply chain.

In this guide, we’ll explain the most common causes of transit damage and share 10 practical ways to reduce shipping damage while improving customer satisfaction and lowering costs.

How to Reduce Shipping Damage in 10 Steps

1. Choose the correct box strength
2. Use the right box size
3. Eliminate excess movement inside the box
4. Protect fragile items with suitable cushioning
5. Consider product shape and weight distribution
6. Use double wall packaging where appropriate
7. Avoid overpacking or underpacking
8. Test packaging before large shipments
9. Consider how products will be stacked and handled
10. Use bespoke packaging designed specifically for your products

Why Does Shipping Damage Occur?

Before solving the problem, it is important to understand what causes shipping damage.

Packages can be exposed to:

• Drops and impacts
• Compression from stacking
• Vibrations during transport
• Crushing forces
• Multiple handling points
• Poor weather conditions
• Inadequate packaging

A parcel may pass through several warehouses, conveyor systems and delivery vehicles before reaching its destination.

Every handling stage introduces potential risks.

1. Choose the Correct Box Strength

One of the most common causes of shipping damage is selecting packaging that is not strong enough for the product being transported.

Many businesses focus on product weight alone, but factors such as dimensions, shape and transit conditions are equally important.

As a general guide:

• Single wall boxes are suitable for many lightweight and medium-weight products.
• Double wall boxes provide additional strength and rigidity for heavier, fragile or long products.
• Heavy-duty packaging may be required for industrial or export applications.

Selecting the appropriate board grade helps prevent crushing, punctures and box failure during transit.

2. Use the Right Box Size

Oversized packaging is one of the biggest contributors to shipping damage.

When a box is too large:

• Products can move during transit
• Corners may become damaged
• Additional void fill is required
• Protection becomes less effective

A correctly sized box helps keep products secure and reduces unnecessary movement.

At ASC Direct, our Box Builder allows customers to create bespoke boxes using exact internal dimensions, ensuring packaging is designed specifically around the product being shipped.

3. Eliminate Movement Inside the Box

If products can move inside the packaging, they are more likely to become damaged.

Any empty space should be managed using appropriate protective materials such as:

• Paper void fill
• Corrugated inserts
• Dividers
• Protective wraps
• Cushioning materials

The goal is to keep the product securely positioned throughout the journey.

4. Use Appropriate Internal Protection

Not all products require the same level of protection.

Fragile products may benefit from:

• Corrugated inserts
• Partition systems
• Edge protection
• Foam solutions
• Custom protective packaging

The level of protection should reflect the value, fragility and transit conditions of the product.

5. Consider Product Shape and Weight Distribution

A common packaging mistake is focusing solely on product weight.

The shape of the product is often just as important.

For example:

• Cricket bats
• Golf clubs
• Lighting products
• Curtain poles
• Metal extrusions

may all require stronger packaging than their weight alone would suggest.

Long products place additional stress on packaging because boxes can flex, bow and twist during handling.

Products with concentrated weight or sharp edges can also create pressure points that increase the risk of packaging failure.

6. Upgrade to Double Wall Packaging When Necessary

Double wall corrugated packaging offers additional strength compared to standard single wall board.

Benefits include:

• Greater compression strength
• Improved impact resistance
• Better puncture protection
• Increased rigidity
• Enhanced stacking performance

Although double wall packaging may cost slightly more, it can significantly reduce the cost of damaged goods and customer complaints.

7. Avoid Overpacking and Underpacking

Both extremes can create problems.

Underpacking

Insufficient protection can leave products vulnerable to impacts and movement.

Overpacking

Excessive void fill and tightly packed contents can place unnecessary pressure on products and packaging.

The ideal solution is packaging designed specifically for the product dimensions.

8. Test Your Packaging

One of the simplest ways to reduce shipping damage is to test packaging before committing to large production runs.

Consider:

• Drop testing
• Compression testing
• Transit simulations
• Trial shipments

Testing can identify weaknesses before they become expensive problems.

9. Think About the Entire Supply Chain

Many businesses focus only on the delivery stage.

However, packaging may need to withstand:

• Warehouse storage
• Pallet stacking
• Vehicle loading
• Courier sorting facilities
• Final-mile delivery

The more handling points involved, the more important packaging strength becomes.

When selecting packaging, consider the entire journey rather than just the destination.

10. Invest in Bespoke Packaging

One of the most effective ways to reduce shipping damage is to use packaging designed specifically around the product.

Bespoke packaging can provide:

• Better product fit
• Reduced movement
• Improved protection
• Lower void fill requirements
• Reduced shipping costs
• Better customer experience

Using custom-sized corrugated boxes ensures products are properly supported throughout transit.

The Cost of Shipping Damage

Many businesses focus on the cost of packaging but overlook the cost of damaged products.

Shipping damage can lead to:

• Replacement costs
• Refunds
• Return shipping charges
• Customer service time
• Negative reviews
• Lost repeat business

In many cases, upgrading to a stronger box or improving packaging design costs significantly less than dealing with damaged deliveries.

How ASC Direct Helps Reduce Shipping Damage

At ASC Direct, we help businesses create packaging solutions designed around their products.

Our Box Builder allows customers to specify exact internal dimensions, helping to create right-sized packaging that reduces movement and improves protection.

Combined with the appropriate board grade and protective packaging solutions, bespoke corrugated boxes can significantly reduce the risk of transit damage.

Whether you’re shipping e-commerce orders, industrial components or fragile products, choosing the right packaging can help protect your products and your reputation.

Quick Shipping Damage Prevention Checklist

Before shipping your products, ask yourself:

• Is the box the correct size?
• Is the board grade suitable for the product?
• Is there any movement inside the box?
• Have fragile areas been protected?
• Will the package be stacked during transit?
• Does the product require double wall packaging?
• Have you considered the entire supply chain?
• Has the packaging been tested?

If the answer is yes to all of the above, you are already reducing the likelihood of shipping damage.

Frequently Asked Questions

What causes shipping damage?

Shipping damage is typically caused by impacts, drops, crushing, vibration, poor packaging and excessive movement inside the box during transit.

How can I stop products moving inside a box?

Using the correct box size, void fill materials, inserts and protective packaging can help secure products and prevent movement.

Does double wall packaging reduce shipping damage?

Yes. Double wall corrugated packaging provides greater strength, rigidity and impact resistance than single wall packaging.

Is custom packaging better for shipping?

In many cases, yes. Custom-sized packaging reduces movement, improves protection and can lower shipping costs.

What is the best packaging for fragile items?

The best packaging combines the correct box strength, suitable internal protection and a box size that closely matches the product dimensions.

James Palfrey-Smith is the General Manager at ASC Direct with extensive experience in both operations and sales. James is passionate about solving packaging problems, delivering fast customer support, and building lasting relationships. Outside of work, he enjoys outdoor activities like hiking and skiing. A fan of real ale and business podcasts, he continuously seeks personal and professional growth. 

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