Damage in transit doesn't start at the shipping dock. It starts at the corrugate spec — the wrong flute for the weight, no insert to protect the primary, a box that passed a drop test alone but not with the label and closure in place. Three structural decisions prevent most of it:
- Corrugate flute: match it to the actual product weight and distribution method — B flute isn't the answer for everything.
- Inserts and dividers: if the primary can move in transit, it will — and find the one position that causes damage.
- ISTA testing: run the test that simulates your real distribution environment before launch.
The insert that gets value-engineered out to save a dollar is the one that comes back as a dented closure and a one-star review. Make the trade-off visible before production, not after.
Read The Retail Readiness Checklist, or ask for our packaging process overview.
Frequently asked questions
How do I prevent shipping damage to cosmetic packaging?
Start at the corrugate spec rather than the shipping dock. Three structural decisions prevent most transit damage: match the corrugate flute to the product weight and distribution method, use inserts and dividers so the primary cannot move, and run the ISTA test that simulates your real distribution environment before launch.
Which corrugate flute should I use for my product?
Choose the flute based on the actual product weight and the way the product will be distributed. B flute is not the answer for everything, and using the wrong flute for the weight is one of the main ways transit damage begins, long before the box reaches the shipping dock.
Are packaging inserts worth the extra cost?
Usually, yes. If the primary package can move in transit, it will, and it will find the one position that causes damage. An insert value-engineered out to save a dollar can come back as a dented closure and a one-star review, so make that trade-off visible before production.
Why should I run ISTA testing before launch?
ISTA testing shows whether your packaging survives the distribution environment it will actually face. A box can pass a drop test on its own and still fail with the label and closure in place, so run the test that simulates real distribution before launch rather than after damage appears.
