Keeping items secure and contained remain the primary goals for packing pallets, with the help of tools and products designed specifically for pallet applications.  While packaging requirements are unique depending on what you are shipping, essential features lead to the best results transporting pallets.  Shipments destined for warehouses, club stores and other retail outlets are held snuggly in-place using proven pallet-building techniques starting from the base-layer, working upward.

Corrugated Deck Pads and Edge Protectors

Soundly constructed pallets start with firm bottom-layers, provided by several varieties of corrugated material, which also serve to separate pallet layers.  Single, double and triple-wall strengths allow products to be stacked on pallets, including machinery and appliances protected by the hardiest three-layer varieties.

Anti-slip kraft paper pads provide additional friction against movement, keeping items in-place until you want them moved.  Economical white cardboard varieties serve lighter-duty uses, while specialized honeycomb sheets contain voids adding superior protection between layers.

As pallet layers are built-up, edge protectors are fitted at the corners, aligned with corrugated pad liners to create continuity across the entire pallet. Edge protectors run various lengths, depending on how high your pallet is to be built. And printed versions carry messages for handlers, like “do not double stack”.

In addition to corners, pallets are reinforced where strapping comes into contact with box edges.

Strapping Supplies

Once stacked and wrapped, pallets are secured using heavy-duty strapping techniques.  Steel, polyester and polypropylene strapping provide various levels of security, keeping pallet contents in place during handling.

Strapping guards and protectors are used to reinforce contact points where poly and steel straps meet cardboard and other materials subject to strap damage.  Using the proper tensioners and sealers, strapping is tightened to appropriate levels, cut and sealed for shipment.  On the receiving end, strapping shears are used to cut steel bands.

Stretch Wrapping Options

Another commonly used method for holding pallet contents in place is to stretch them securely using plastic films.  Various film widths and thicknesses serve specific uses ranging from general wrapping to enhancing puncture resistance.

Stretch wrap is applied by hand, or by machines, each approach requiring particular materials for the best results.  Colored films allow shippers and receivers to coordinate freight using color schemes, and opaque varieties keep contents out of sight during transit.  Additional specialized wraps include anti-static versions capable of reducing static charges during shipment.

Clear and black materials are standard, with tinted varieties available for specialized applications.  Vented and blown stretch film assist with food applications, where air circulation is required, as well as adding further puncture resistance to irregularly shaped loads.

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For trouble-free transfers, take stock of your most-shipped items and then set your shipping room up with the supplies needed to ensure efficient delivery of your goods. Packaging providers are great starting points, bringing valued recommendations and access to exactly the materials required to complete your shipping projects.

Packaging and shipping efforts tackle small items shipped regularly, as well as bulk shipments requiring pallet sized solutions. Whatever your needs, efficient freight operations start with properly-sized boxes, labels, tape and poly bags for certain items.

Corrugated Boxes Set the Standard

Shipping needs vary across industries and vendors but most solutions involve the use of some type of corrugated box.  Boxes are configured in countless sizes and shapes, with custom varieties produced for shipping specific items.  Sizing boxes properly is important for several reasons, including product security and cost control.

Standard boxes serve general use applications, providing economical alternatives when single-wall corrugated material is adequate protection for the items being shipped.  Heavy-duty, double-wall construction reinforces product protection, offering greater impact absorption and puncture resistance.  Multi-depth boxes are scored to fold at multiple points, allowing items of various sizes to be packed in the same sized boxes.

Boxes should be sized to accommodate products insulated with adequate amounts of fill.  Foam, paper and bubble-wrap fill options each come with a price attached, so it is important to find the balance point between adequate product protection and wasteful over packing.  Packing material providers offer recommendations and box sizing information to help identify the best strategies for shipping your products.

In addition to standard boxes, shippers use a variety of application-specific corrugated boxes.  Boxes designed for specific uses include those used for computers and electronic components shipped regularly.  Custom impact absorbing inserts are used alongside boxes to cradle sensitive components in shock-resistant units that protect them in transit.  Similar custom-fitted box inserts help transport hazardous materials safely, while insulated boxes are essential for maintaining freshness of temperature sensitive items.  Shippers of paper goods and printed materials utilize hanging file boxes and those sized especially for printers.

Tape and Labeling Supplies

Labels send valuable messages to receivers, so pre-printed and custom made varieties are regularly utilized by shippers of all sizes.  Instructive labels also ensure proper handling by freight companies, whose staffers heed warnings of “Fragile” or “Glass”.

C.O.D. labels instruct delivery personnel to collect payment when appropriate, and “Packing List Enclosed” placards direct receiving rooms toward valuable documentation concerning the freight.  Labels required for regulatory compliance are also available in pre-printed quantities, alerting handlers to hazardous materials, compressed gas, and other sensitive freight.

Tape needs are not the same for every shipping room, but standard carton sealing varieties are a starting point for most shippers.  Standard and heavy duty options are easily dispensed from hand-held units.  Specialized security tapes and pre-printed options are appropriate for some applications, providing tamper resistance and handling instructions on printed rolls.

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As shipments leave your facility, important messages go out with them – from package contents to destination information, each contained on adhesive labels.  And some of the items you frequently ship may include substances regulated by law, requiring particular labels and tags.

While every shipper has different needs, labels and tags assist warehousing and shipping operations at most business locations.  Start-ups and shippers with changing needs benefit from professional packaging consultation, which guides them to solutions most appropriate for their individual shipping and packaging requirements.

Inventory Labels Help Track and Rotate Stock

Maintaining tight tabs on inventory and keeping the revolving door of shipments flowing without interruption requires efficient solutions, like pre-printed and blank colored labels.  Pairing pre-printed calendar month labels with numeral stickers helps warehouses identify exactly when each product was placed in inventory.  Slow-moving goods and improper stock rotation become immediately recognizable when date labels are affixed.

Even before goods become inventory entries, they are counted and checked-in by receiving clerks.  Pre-printed labels reinforce accountability standards, requiring receivables to be tagged “counted” or “inspected by”, before being allowed in-stock.

Storage facilities using quarterly tracking methods benefit from pre-printed labels with first through fourth quarter designations clearly printed on them.  And when text labels are more appropriate than calendar numbers, packaging suppliers provide days- of- the- week stickers to take the guess-work out of rotation labeling.

For custom-conceived applications, various-sized circular and rectangular labels allow color-based organizational schemes to flow smoothly, with or without additional information added to them.  Bright fluorescent colors are favored, sold in packs containing sheets of each colored variety.  For high volume uses, rolled goods are easily stored in wall-mounted and table-top dispensers, which each hold multiple rolls of adhesive labels.  Many models are adjustable, accommodating rolls of various widths and core diameters.

Shipping and Handling Labels Send Important Messages

Shipping and handling labels communicate silently, conveying important messages to individuals and departments receiving freight.  Their presence is mandated when safety is at stake, but stick-on labels are also used to provide countless notifications about shipment contents, packing lists, and handling requirements.

Pre-printed Department of Transportation (D.O.T.) labels ensure compliance for shippers working with potential hazardous materials.  Compressed gas, flammable materials, and corrosive compounds are each clearly labeled to meet D.O.T. standards.  Colors are added to support danger messages, like yellow labels identifying hazardous waste.

Special labels guide handlers encountering your packages in-transit.  Fragile, handle-with-care, and glass-contents are familiar heads-up designations found on labels, but pre-printed instructions also include messages like “C.O.D”, alerting delivery drivers to collect payments before leaving  goods behind.

Bilingual labels serve shipments bound for non-English speaking neighbors, while pre-printed graphics-based labels go one step further; relying on international pictorial messages easily understood by viewers from all parts of the world.

Whether mandated for safe storage and shipment or included as part of your own organizational structure, adhesive labels are invaluable for maintaining your shipping department flow. Pre-printed varieties also assist warehousing efforts, tracking inventory by date and identifying goods by color.

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Stretch film addresses specific shipping tasks, so the best varieties to use are chosen based on the size and configuration of your routine orders.  Manual stretch film options serve businesses of all sizes, each type supported by a full range of film dispensers and accessories.  Facilities utilizing greater automation benefit from machine stretch film approaches providing consistent high-volume stretch film capabilities.  Whatever your shipping and warehousing needs are, packaging suppliers have stretch film solutions available to reduce damage loss and keep your shipping operations flowing smoothly.

Machine and Manual Stretch Film Preferences

Films are stretch by-hand, or with the help of automated wrapping machines.  The best method for each shipper to use depends on volume, order-size and a host of other individual factors.  Cast Machine varieties are capable of stretching film up to 250%, providing tightly contained pieces for shipment.  And irregularly shaped bundles benefit from Blown Machine Stretch Film, which is puncture resistant and performs well under a variety of extreme conditions.  Crystal-clear films help identify packing lists and allow for easy product identification, but opaque blown film varieties are also available to conceal shipment contents.

Hand stretch film is also drawn from rolls, but stretched manually using hand-held dispensers rather than being pulled taut by machines.  Hand films are effective for containing uniform loads, providing several distinct options for items of varying weights.  60-Gauge film, for example, is appropriate for loads weighing up to 1600 pounds, while 120-Gauge material firmly secures up to two tons of goods.

Films used for special applications include varieties with built-in anti-static agents, as well as options of assorted colors. Colored film provides easy inventory control, and allows shippers to identify themselves with unique outer-wrap colors.  For irregularly shaped shipments or jutting parcels, packaging suppliers provide clear blown film, or a black variety, which completely hides items from view once wrapped. Corrosion inhibitors are present in VCI Stretch Film, making it the perfect choice for wrapping large metal parts.

Further accommodating hand stretch film users, products like Goodwrapper and Extended Core films are outfitted with built-in dispensers, keeping them at the ready without additional equipment requirements.

Bundling Film for Smaller Loads

Not every shipping effort is pallet-sized, so convenient hand bundling films provide stretched-in protection for smaller parcels.  One-handed operation draws film from roll-dispensers, either built-in or reusable.

Stretched bundling film acts like tape does; holding items securely in-place during transit, but is a more affordable solution than strapping and tape.  Colored film varieties help identify tubes, boxes, and other bundled items, allowing efficient warehouse inventory management.

Whether shipping fully-loaded pallets or simply bundling related parcels, stretch film alternatives provide consistent low-cost protection during transit.

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Poly bags provide essential protection in nearly unlimited sizes and shapes, making them ideal for many products.  Specific bag styles address particular needs for packaging, including poly bag options used primarily to protect items during shipping and storage.  Various thicknesses of bag material provide diverse solutions, supplying inexpensive thin poly coverage or high-strength fortifications as required.

Whatever you need bagged, polyethylene alternatives are available is styles, sizes, shapes and densities appropriate for your project.

Poly Bag Styles

Polyethylene is the most widely used form of plastic, with low-density and linear low-density poly materials commonly used for making bags.  Several styles exist, each appropriate for certain applications, and some bags are custom-crafted for specific contents.  Balancing the level of protection you need with the costs of thicker bag materials provides affordable safeguards, without compromising the standards required to keep your products safe.

Flat – Flat poly bags are used when clear presentations are desired, but affordability is paramount.  The cost-effective approach highlights bag contents, providing limited protection against dirt, dust and handling damage.  If you regularly ship documents and other flats it pays to keep thin poly bags on hand to protect them in transit.

Gusseted – Irregularly shaped or bulky items benefit from gusseted poly bags designed to expand when filled.  Gussets create a form-fitted look, without using custom bags and serve a variety of packaging needs.

Colored – Poly materials are available in multiple colors to support your branding strategy or shield bag contents from light and scrutiny.  Packing your own products in poly bags from bulk stock gets a merchandising enhancement from the use of colored poly bags, which sets them apart from clear competitors. Clear bags can also be embellished with colorful printed graphics and logos.

Re-sealable – Depending on the items you regularly work with, re-sealable poly bags might provide the best solutions for your shipping room.  Options include familiar grip-seal closures that pinch closed as well as slide alternatives incorporating a plastic slider to get the job done.

Additional Options

Bag strengths come in light, medium and heavy-duty alternatives, including high tensile strength varieties that allow enhanced protection even with thin-walled bags.  And to dial-in protection even further, some poly bags are crafted specifically for certain items.

Garment bags, for instance, keep clothes shielded from harm during transport. And mattresses are regularly protected in the same way, with large fitted poly covers. These and other specialty poly bags are available in rolls for dispensing as needed in higher-volume situations.

Special poly specimen sample bags are used to preserve medical samples and sensitive crime scene evidence.  White block alternatives incorporate writable sections into each bag for easy labeling.

Shippers use large poly bags to guard against damage during transport. Pallet covers and bin liners are precisely fitted for their purposes, in clear or black poly varieties.

Additional bags and accessories are available from packaging providers prepared to furnish quotations for your shipping and packaging needs.

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To a certain extent what you’re shipping dictates the best ways to get the job done. Electronics, for example, are well-suited for padding with non-static wraps and packing peanuts that reduce electrical charges during shipment, and so on.  Use all the options available to devise the best void filling strategies for items you ship regularly, including foam, bubble products, loose fill and kraft paper.

Bubble Wrap Varieties

Incident-free shipping begins with appropriately sized boxes, which should not leave excessive voids for filling.  Some space is required to accommodate cushioning materials, but filling large voids is a waste of resources.   When irregularly shaped items create open spaces in boxes, bubble wrap provides a sturdy first line of defense against damage.

Bubble products generally represent the first layer of insulation closest to boxed contents, allowing them to be secured snugly. To make the wrap, air bubbles of various sizes are molded into plastic sheeting used to protect products from harm.  The material is available in rolls with or without perforations as well as sheets and pouches, which allow contents to be slid-in before sealing.  Larger bubbles provide heavy duty protection, and anti-static air-bubble products are used to minimize electrical charges when shipping electronics.   Specialized adhesive bubble wrap is also available, equipped with sticky surfaces that cling to box contents without leaving residue.

Foam Fillers

Foam helps shippers in two distinct ways:  Foam wraps and corners/edges.  Conventional air foam products mimic bubble wrap, protecting packages in much the same way bubble options do.  In fact, the foam sheets also derive their effectiveness from the air pockets they contain, cushioning against impacts during handling.  Air foam sheets are available in a variety of widths, sold in rolls with or without perforations.  Pre-cut sheets and pouches provide additional options for using foam fillers.

Foam corners and edges protect boxes within boxes, cradling them tightly inside outer packaging.  The expanded polystyrene inserts provide protection against impact during transport, and they also reduce exposure to harmful vibrations.

Loose Fill and Kraft Paper

Light, irregularly shaped items are adequately secured with crumpled kraft paper used to fill voids. Multiple sizes and styles exist, included wax-paper options and even poly coated kraft paper for specialty applications.  Materials range from 100% recycled, to combination papers using virgin fibers.  Kraft paper is sold in precut sheets and rolls easily installed on horizontal or vertical paper cutters.

Loose fill made from peanut shaped polystyrene is used to cushion box contents from all sides, providing evenly distributed impact resistance and shock absorption.  Virgin and recycled options provide the same levels of protection, with anti-static versions limiting static charges when shipping electronics.  Completely biodegradable options made from natural materials eventually disappear without a trace.  Convenient gravity dispensers make loose fill options ideal for a wide range of shipping room applications.

Flexible fill solutions exist for the items you ship most.  Bubble, foam and loose fill options work together to provide comprehensive cushioning for your shipping output.

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Strategies have been tested to create a bulletproof one-size-fits-all shipping solution that ensures timely turnaround without adding too much to the cost of production and delivery – only to find that each shipper has unique needs.  The best approach for one company may not address the particular needs of another, so custom tailored strategies are developed on a case-by-case basis.   Regardless of the scope of services required a wide range of companies consult with contract packaging companies to implement workable individual packaging and shipping solutions.

Flexible Fulfillment Options

There are several ways to get products into the hands of consumers, each requiring a different level of commitment and commensurate understanding of the packaging industry.  Manufacturers and wholesalers either choose to play active roles in packaging their products and sending orders out, or they rely on contract packaging services to complete some phases of the operation for them.

When turnkey packaging contracts are selected, outside companies handle every aspect of the process required for packaging individual products – from design and materials sourcing to warehousing and logistics.  Professional packagers work with clients to establish production and order fulfillment schedules, which are followed precisely.

Of course this hands-off approach does not suit all businesses.  For some shippers, contracting the entire process may be cost prohibitive or inefficient. But only a fraction of these companies invest in the specialized infrastructure required for operating autonomous packaging facilities in-house.  Most business need flexible solutions, allowing them to contract services they can’t provide, while still maintaining well-stocked shipping facilities for direct order fulfillment.

Shipping Departments

Assembly, packing and shipping are tasks completed by regular staffers at some facilities, while others contract with outside providers to get the job done.  At small to medium sized facilities, filling orders quickly is accomplished by in-house shipping departments, which vary in size and responsibilities.

Packaging suppliers provide insight into new products and furnish recommendations about which shipping methods provide the highest levels of protection and security during transit.  For instance, commonly shipped items like computers, files, and electronic components are accommodated by specialized boxes and inserts designed explicitly to hold certain items securely in-place.

Packaging suppliers know how to protect irregularly shaped goods during shipment, furnishing countless standard sizes and shapes of corrugated boxes. Kraft paper and other fill materials round out the packaging requirements for individual units, before they are grouped into cartons.  Master cases and display-packs are determined based on the size and shape of each unit, creating secondary layers of protection for high-volume orders shipped on pallets

Well-equipped shipping rooms are equally prepared to ship small parcels, maintaining inventories of appropriately sized padded mailers and bubble-wrap lined envelopes for filling small orders quickly.  Nylon reinforced versions add extra protection against tears and punctures.

Additional shipping supplies – tape, wrap, bags, foam and envelopes keep shippers primed to turn orders around quickly and efficiently in-house.

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Mailing Bag Materials

Mailing envelopes are designed to carry flat and nearly flat contents requiring varied levels of protection and security during shipment.  To handle a range of commonly shipped items, mailing bags and envelopes are constructed from a variety of materials.

Paper – The industry standard for mailing casual documents and flat parcels, paper is inexpensive and provides adequate protection for a range of printed materials.

Ship Lite Envelopes – Providing about 6 times the level of protection afforded by standard mailing envelopes, Ship Lite mailers are constructed of paper reinforced with durable fibers.

Poly Mailers – Polyolefin construction adds further fortification against moisture and accidental damage during shipping.  The material is stronger than reinforced paper and comes in clear varieties that highlight envelope contents.

Tyvek – Known for its highly visible application as house wrap. Tyvek provides high levels of puncture and tear resistance for precious envelope contents.  The material is about ten times stronger than paper and provides better protection against moisture than other packaging materials.

Nylon Reinforced Mailers – When padding is not required but extra resistance against tears is desired nylon reinforced mailers provide lightweight alternatives that save on freight costs.  Self-sealing and expandable options provide economical protection for flat parcels.

Types of Envelopes and Mailers

Padded – Some mailing bags are cushioned for extra protection, providing shock absorption during transit – especially for items that are not quite flat.  Encased in Kraft paper exteriors, fiber padding and bubble wrap serve similar functions in padded mailers, insulating package contents from rough handling. Specialized versions are available with colored plastic film exteriors, as well as metallic silver Cool Shield thermal mailers designed to protect package contents from extreme temperatures.

Expansion Envelopes – Gusseted shippers grow as they are filled with additional documents.  The flexible alternatives are constructed from a variety of materials, including those resistant to moisture and punctures.

Extra Long – Long mailers, made of Polyethylene and other materials accommodate artwork, posters and wallpaper rolls during shipment. Legal documents and other extra-long printed materials are also safeguarded in extra-long mailing envelopes.

Tamper Evident – Extra security measures are added to tamper evident mailing envelopes, incorporating verifiable physical features into the seals.  Once opened, the mailers cannot be returned to their unadulterated states.

Flat Mailers – Using tabs as closures, flat mailers provide stiff enclosures for documents and photos.  Self-sealing options can be re-secured easily, to keep documents secure between viewings.  For applications requiring rigid envelope structure and padding, Jiffy Rigi Bags contain both.

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What Makes This Box So Special?

Corrugated boxes are lightweight yet strong enough to handle really heavy loads because they are made of corrugated paperboard – hence the name. The corrugated paperboard has rows of air columns that act as a protective cushion aligned with paper columns that make the box very sturdy.

Because of these superior strength and protective aspects, corrugated boxes move more than 95 percent of all products that are shipped in the United States. These boxes are also very “green,” making up more than half of all U.S. recycled paper, and more than six million tons of old boxes are recycled annually by grocery stores.

A Corrugated Box For Almost Every Need

There are corrugated boxes in many sizes, shapes and depths so that whatever they hold fits well and will not be damaged by moving around inside. Most everyone has used the basic square corrugated box, but there really is an option for almost anything that needs to be moved, regardless of its shape or size.

• Multi-Depth – If you’re packing items of different sizes, this is a real time-saver. These boxes have scoring on the sides that lets you cut down the box to whatever height you need without any special tools. Buy several of these and then create the box that’s best for the job.
• Telescoping – As the name describes, these boxes come in two or three pieces that can slide to a desired length or height. If you have a long or tall item to move, this is the box for you.
• Side-Loading – There’s nothing more frustrating than trying to fit a flat object into a cube-shaped box. Side-loading corrugated boxes open along the ends and are ideal for mirrors, pictures or any other flat object.
• Corrugated Trays – This is your choice when moving small, light objects or items that can’t be boxed like plants. Though not very deep, these trays are just as strong as their larger counterparts.

They’re Not Just For Moving

Today’s corrugated boxes are also being used in ways that keep them firmly rooted in one place. File storage boxes can be found in almost every home or office to store important paperwork. There are large boxes that will hold hanging files and smaller versions for index or business cards. These stationary boxes often come with attractive designs and special covers for extra protection.

Whether you’re filling them for a move or for on-site storage, corrugated boxes are a reliable, cost-effective way to get the job done.

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Packaging solutions are available for whatever you ship including boxes specifically designed to handle particular products.  Using the proper box is essential for minimizing per-unit freight costs and maximizing profits. Consider the following options before consulting with packaging professionals to dial-in your shipping department needs.

Standard and Heavy-Duty Corrugated Boxes

Corrugated boxes come in hundreds of sizes to facilitate shipping diverse contents.  The dimensions and vulnerability of the products you ship are key factors to consider when outlining the best strategies for your facility.  The boxes you select for standard use should be large enough to accommodate adequate protective fill, but not oversized with excessive voids. Filling unnecessary spaces with bubble, foam, and Kraft paper fillers costs money, reducing profitability for your company.

Heavy-duty boxes of single and double-wall construction provide added protection during transit, especially when greater stacking strength is needed.  And for the greatest flexibility, shippers choose multi-depth boxes, which accommodate multiple pack sizes without modification.

Cargo Boxes

Effective bulk shipping on pallets is sometimes accomplished using stretch films that wrap and secure items during transit.  Cargo boxes are used when additional reinforcement is required and when irregularly shaped items are hard to secure.

Gaylord containers and other bulk cargo boxes provide flexible bulk shipping solutions, including telescoping options and easy-load versions that can be covered before shipping.  Triple-wall cargo boxes are designed to protect your most vulnerable items, allowing them to be stacked on pallets without expensive crates.

Application-Specific Boxes

Specialized boxes accommodate specific items, allowing consistent output and high levels of protection from your shipping department. Using makeshift approaches doesn’t add-up when dedicated application-specific boxes are available for the items you regularly ship.

Printers, for example, utilize boxes specifically sized for reams of printed materials. And hanging file boxes provide shipping and storage solutions for other paper-heavy industries. Moving boxes come in all sizes, equipped with inserts for particular items like lamps and dishes. And clothing is easily transported in wardrobe boxes that function like portable closets.

Hazardous materials are safely transported, contained in special boxes utilizing custom-fitted inserts to hold jugs, cans, and other containers snuggly in-place.  Food and medical industries are served by insulated boxes that help maintain consistent temperatures during transit.

Computers and accessories with uniform sizes are shipped in job-specific boxes that keep delicate electronic components protected.  And suspension boxes, which hold sensitive items within special shock-resistant frames, provide the utmost security for fragile goods.

Regardless of what you ship, packaging suppliers are equipped to provide guidance and boxes that get the job done efficiently, with the proper balance of protection and value.

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