The Most Common Reasons Packages Fail Testing

At Gaynes Testing Lab, we understand that no one wants to hear that their package has failed a test. Unfortunately, it happens, often for predictable reasons. By understanding these common pitfalls, you can design stronger and smarter packaging. This will help you reduce costly delays.

Reasons Packages Fail Testing

Here are three of the most common reasons packages fail:

1. Inadequate Packaging Design

Many packaging failures stem from issues with the box itself. Is it too thin? Is the cardboard of the wrong type? Is it not rated for the weight it carries? If your primary packaging cannot withstand stacking, drops, or vibration tests, it won’t survive transit.

It’s essential to choose the right materials and designs for your specific products. Investing in proper packaging can ultimately save you from failures down the line.

2. Poor Internal Protection

Even if the box is strong, internal protection is crucial. Fragile items require cushions, foams, air pockets, or molded inserts that can absorb shocks. In many of the tests we conduct, we discover loose or insufficient protective materials. These allow products to shift, crack, or puncture the packaging.

Make sure that your internal cushioning materials are adequate for the specific type of product you are packing. Proper internal protection can prevent failures in transit and during tests.

3. Incorrect Container Fit

If the product does not fit snugly within the packaging, you are asking for trouble. Oversized boxes create extra room for impacts, while undersized boxes put pressure on seals and edges. Both can lead to test failures, whether in compression, drop, or vibration trials.

A proper fit is essential for ensuring the integrity of your product during transport. Always check if your packaging is appropriate for the size of the product.

What Happens When You Fail?

If your package fails a test, we document every result. This includes photos and videos of the testing process. After failing, we share our findings with you. While we don't design packaging, we provide invaluable insights and non-binding advice to help you address the issues.

Once you’ve improved your design, you can resubmit it for retesting. This iterative process is vital. Remember: failing early in the lab beats failing in the field. Let us help you get it right.

The Importance of Testing

Testing is an essential part of the packaging process. It saves time and money in the long run. When you test your packaging thoroughly, you're less likely to face issues after the product has already shipped.

Taking the time to prepare and test your packaging can prevent significant headaches later on.

Best Practices for Successful Packaging

To ensure a successful packaging strategy, follow these best practices:

1. Choose Quality Materials: Ensure that the materials used for packaging are suitable for the products. Strong and appropriate materials will enhance the survivability of your package.

   
   

2. Conduct Comprehensive Tests: Utilize various testing methods to simulate real-life scenarios. This can include drop tests, vibration tests, and compression tests.

   
   

3. Review and Revise: If your package fails, take the insights we provide to make necessary adjustments. Continuous improvement is key to successful packaging.

   
   

4. Collaborate with Experts: Consult with testing laboratories like Gaynes Testing Lab. Our expertise can be invaluable in helping you refine your packaging strategy.

   
   

Understanding the common reasons packages fail can save you from costly mistakes. By refining your packaging design based on our insights, you can avoid failures. Take advantage of our testing services to ensure your packaging is ready for the challenges it will face in the field.

Don't forget: it's better to identify issues in the lab than in the marketplace. Reach out to us today so we can assist you in getting it right.