UPS: Internal Packaging

Internal packaging provides shipment protection during the distribution process. Good internal packaging should have the ability to protect the product from shock and vibration, and then return to its original shape to provide further cushioning. There are a number of internal packaging materials and methods to consider before shipping a package.

Internal Packaging Materials
Loosefill Peanuts Primarily used as space fillers for lightweight items. They are not recommended for use with flat, narrow, or dense products that may migrate within the package because they shift and settle during the distribution cycle. This shifting and settling allows the product to shift within the package, exposing it to a higher probability of damage. The minimum guideline for Loosefill Peanuts is to use a minimum of three inches (7.62 cm) of them around all sides of the container. In addition, the package will need to be overfilled by at least one to two inches (5.08 cm) to allow for shifting and settling. Encapsulated-air Plastic Sheeting Packing material made of air bubbles that are encased between two poly sheets as they are sealed together. This process allows encapsulated air to provide a cushion to protect against shock. Encapsulated air provides good cushioning for lightweight items, is flexible, and cuts to wrap virtually any shape or sized product. It should not be used to wrap heavyweight products. When using encapsulated-air plastic sheeting, use several layers to ensure that the entire product is protected, including corners and edges. Polyethylene Foam Sheeting Lightweight, soft, resilient foam sheeting material that provides excellent surface protection and cushioning properties. Ideal for protecting lightweight items. Inflatable Packaging Inflatable packaging uses air pressure to secure and hold products in place inside the shipping container, and provides an air barrier of cushioning. Extreme climate conditions will affect the amount of air pressure in the bags. In extremely cold conditions, the volume of air will decrease, causing extra space inside the package and increasing the risk of product damage. Extremely hot conditions will cause the air bags to expand, which can create stress on the seam of the shipping container. Altitude variations also affects the volume of air inside the air bags. Traveling from high to low altitudes (for example, packaging a shipment in Denver, Colorado, and shipping to New Orleans, Louisiana) will cause the air bags to decrease in size, and traveling from low to high altitudes will cause the air bags to increase in volume. Foam-in-Place Foam-in-Place is formed by a chemical mixture that expands and forms a protective mold around contents. Foam-in-place forms a mold around any product, supports corners, protects edges, and is useful where cushioning is needed. For maximum effectiveness, the foam-in-place must be evenly distributed around the items. Otherwise, the foam will not protect the product. Select the appropriate density of foam to meet packaging needs, which can range from void-fill applications to high-performance cushioning. Kraft Paper Kraft paper is wrapped and crumpled to fill empty space inside a package with light-to-medium weight, non-fragile items. When using kraft paper, tightly wad the paper and use at least four inches (10.16 cm) around and between the contents. Make sure that there are at least four inches (10.16 cm) of kraft paper on all six sides of the box. Paper Cushioning Multilayered (not-newspaper or newsprint) paper padding ideal for wrapping medium to large sized, non-fragile items and those that may require moisture absorption. Paper cushioning is excellent for filling empty spaces. Expanded Polystyrene Foam (EPS) EPS is a moldable, lightweight, low cost foam with minimum impact cushioning abilities. EPS is often designed with ribs that will compress on impact and return to its original shape. It is not as resilient as other poly foams, such as polyethylene and polyurethane. EPS is well suited for less fragile shipments. Polyethylene Foam (PE) PE is a low density cell foam. Molded or fabricated PE offers superior shock and vibration reduction capacities, making it suitable for cushioning high value or fragile items. Polyurethane Foam (PU) Polyurethane is a low density, flexible foam that offers good shock absorbency and resiliency. Because it is a lightweight, flexible foam, it is more suitable for light loads. Corrugated Board Two or more layers of single or double wall corrugated board may be laminated together to form blocks or pads. These pads can be used to form a protective shield between the product and container. Corrugated pads are best used with heavy, semi-to non-fragile products. Corrugated board can be shaped to form trays, liners, partitions, and other package accessories that work to cushion semi-to non-fragile products and increase the integrity of the shipping container.

Cushioning Methods
Blocking and Bracing By using a resilient material, you can block and brace shipments by absorbing the shock energy and direct it towards the strongest point of the product. The blocking and bracing method is the preferred cushioning method for heavyweight packages. Floatation/Stuffing Floatation is a method of surrounding an object with small pieces of cushioning material that shift or flow to fill empty space in the package and distribute the impact over the entire surface of the product. This method works best when combined with other packaging methods. Wrapping Using sheet material of various types, individual pieces are wrapped to protect small items. This method is not adequate for the protection of heavyweight products. Suspension Suspension is a method of holding the packaged product away from the sides of the container for protection. Materials used for suspension are straps, tape, slings, poly-film, or other supports that can act as flexible restraints. Molded Enclosures Molded enclosures form to the shape of the product and distribute the force across the product.