Avoiding Scary Mishaps: 7 Common Packaging Mistakes and How to Avoid Them

This may be the season of surprises and frights, but in the industrial packaging industry, scary packaging mistakes can be costly, damaging, and potentially impact future customer relations. Many manufacturers depend on their wooden crates, pallets, and other packaging materials to get their products safely from point a to point b.  No one wants their products to arrive broken or contaminated, especially when money and time is on the line. To help avoid these nightmares, we are exploring common packaging mistakes and ways to help prevent them. So, grab a flashlight, turn off the lights, and let’s explore the spooky side of packaging!

Using the wrong materials for packaging is like using a flimsy mask to scare a trick or treater – it won’t work well. For instance, choosing lightweight material for heavy products or a rigid material for a product that needs flexibility can result in damaged goods. Also, materials that aren’t moisture-resistant, like some types of cardboard or untreated paper, are vulnerable to weather-related damage and leaks, which can be especially bad during transit.

It is important to work with a supplier that will conduct a thorough product analysis before deciding on which packaging materials will work best for you. This includes evaluating weight, size, fragility, and the transportation environments that your products may encounter. For products that will be shipped through harsh environments, it is crucial to use durable materials and have enough integrated packaging in place. This could include using corrugated cardboard, foam padding, or plastic materials. The right material will save you time and money in the long run.

Here we are to talk about integrated packaging again because in-transit damage is a nightmare for all involved! Cushioning materials like bubble wrap, foam inserts, or corrugated materials help to absorb shock and reduce the risk of damage and packaging failure. Without proper cushioning, even a slight shift or impact could result in cracked, broken, or dented products.

Invest in the right integrated packaging for each type of product, especially for fragile items. Make sure that you are working with someone with attention to detail to ensure that cushioning materials are properly placed around all sides of the item to keep it stable during transport. Custom-fit packaging, where cushioning is specifically shaped to the product, offers optimal protection and prevents shifting to avoid packaging mistakes.

Overpacking may seem like a safe approach, but it’s not only wasteful and environmentally harmful but can also increases packaging mistakes. On the flip side, underpacking can leave products vulnerable to damage. Both scenarios create an inefficient supply chain and add unnecessary costs that impact your ROI.

At Conner, we use a total cost approach to integrated packaging. We strive to find your “sweet spot” where not only your products are safe, but also your pockets. We take into account your products, materials, handling, and logistics to find the best packaging solution available. Many people may think that the more packaging, the better, but in reality, at a certain point extra materials are overkill and add very little durability. It’s important to work with a design team that turns over every stone when finding your packaging.

Quality control might seem like a small step, but ignoring it is like skipping the haunted house inspection, you’re almost guaranteed a scare! Poor quality control can result in defective packaging reaching its destination, which may cost you more money in labor, warehousing, replacements, and returns.

It is vital to establish a quality control process for your packaging or to work with a supplier that does, especially before high-volume shipments. Train employees in what to look for in terms of defects and make routine checks part of your standard operating procedure. Quality checks should ensure that packaging meets strength, durability, and appearance standards.

Not accounting for environmental factors like temperature and humidity in transportation can be disastrous! Moisture, heat, or extreme cold can weaken packaging materials, warp materials, and ruin product quality. Certain materials may become brittle in cold weather, while others soften and lose integrity in high humidity.

Choose packaging materials that can withstand the anticipated environmental conditions of both warehouse storage and transport. For example, keep pallets stored inside so they are not affected by snow, rain, or other environmental factors that can impact how they operate.

Different industries may have packaging regulations that ensure product safety, especially when it comes to those in the defense sectors, pharmaceuticals, or working with hazardous materials. Failure to adhere to these can lead to recalls, fines, and serious safety concerns, not to mention lasting reputation damage.

It is important to familiarize yourself with all regulatory requirements that apply to your industry and to make sure your supplier is also aware. Update your packaging to meet any new or revised standards and work closely with regulatory bodies if necessary. Regular training on compliance requirements is also beneficial for your team to avoid packaging mistakes.

As we have stated many times in this article, working with the right supplier can make or break your ability to avoid packaging mistakes. The right supplier will help you to get the most out of your packaging by choosing the right materials, research the protection you need, maintain quality control, help you to adhere to regulations, and optimize your supply chain.

There are many choices when it comes to choosing to help you with your packaging. A choice not to be made lightly. A scary mishap can derail your production line, and nobody has time for that.

Avoiding these spooky packaging mistakes doesn’t require a crystal ball or a magic spell—it simply requires a proactive approach and a commitment to quality. By choosing the right supplier to help you get the most out of your packaging and to find the best packaging solution, it will help to keep your products safe and most importantly keep unnecessary costs down. This Halloween, let the scares stay in the haunted houses, not in your shipping department. With a little care, you can have a consistently excellent packaging experience that builds trust and keeps scary packaging mistakes away for good.

Reach out to see how Conner can help you get the most out of your packaging today.