Holiday e-commerce volumes push packaging to its limits. Trailers are overfilled, handling is rushed, and parcels endure more drops and vibration than usual. Without proper testing, even well-designed packaging may fail under peak season conditions, leading to damage, costly returns, and dissatisfied customers. Why Peak Season Testing Is Critical Higher stacking pressures: Boxes face extreme compression in full trailers. More frequent handling: Extra scans and transfers increase drop risk. Transit vibrations: Long-haul shipping amplifies mechanical stress. Environmental extremes: Moisture and temperature swings impact materials. Peak conditions require packaging that goes beyond normal performance thresholds. Types of Packaging Tests for Peak Season Compression testing: Measures stacking strength of corrugated boxes. Drop testing: Simulates impacts during warehouse and carrier handling. Vibration testing: Evaluates product protection in long-haul transit. Edge crush test (ECT): Determines box wall strength against vertical pressure. Moisture testing: Assesses packaging durability in variable climates. Balancing Cost and Testing Rigor Not every SKU requires the same testing intensity. Packaging buyers should prioritize: High-value or fragile products. Items with past return/damage history. Heavy SKUs prone to crushing or shifting. Subscription or seasonal kits with multiple components. Testing can be scaled to focus on products where risk is highest. Holiday Packaging and Supply Chain Alignment Testing should be tied directly to peak-season logistics strategies. Packaging must: Meet retailer compliance standards. Withstand real-world shipping simulations. Be validated before production ramps for holiday campaigns. Holiday Packaging Solutions with Brown Packaging Brown Packaging helps brands test and validate packaging for peak season. Using industry-standard methods, we ensure designs hold up against compression, vibration, and environmental stress during high-volume shipping. Contact us to safeguard your holiday packaging. References ASTM International. (2023). ASTM D4169: Standard Practice for Performance Testing of Shipping Containers and Systems.International Safe Transit Association (ISTA). (2022). ISTA Test Procedures for Packaged Products in Transit.Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts

The holiday season is the busiest—and most demanding—time of year for e-commerce packaging. Higher shipping volumes, faster turnaround times, and rougher handling conditions increase the risk of product damage. For packaging buyers, preventing costly returns and protecting brand reputation requires balancing structural strength, material efficiency, and smart design choices. The Risks of Peak Season Shipping During peak periods, parcels move through more touchpoints than at any other time of year. This creates conditions that amplify damage risks: Increased handling: More scans, transfers, and repacks. Stacking and compression: Trailers and warehouses filled to maximum capacity. Temperature extremes: Exposure to cold, moisture, or fluctuating environments. Rushed labor: Faster fulfillment increases the chance of rough handling. Key Packaging Strategies for Damage Prevention Right-size boxes: Eliminate empty space that allows product shifting. Reinforced materials: Choose double-wall or high-performance corrugated for heavy SKUs. Protective inserts: Foam, corrugated, or molded pulp provide stability. Edge and corner protection: Absorb shock during stacking and transit. Moisture resistance: Add coatings or liners for weather-sensitive deliveries. Testing Packaging for Peak Loads Simulation testing before the holiday rush ensures packaging is fit for purpose: Vibration testing: Replicates conditions of long-haul transit. Compression testing: Confirms stacking strength under peak loads. Drop testing: Evaluates impact protection across handling points. Investing in testing reduces the risk of large-scale returns that erode profit margins. Balancing Cost and Performance Not every product requires heavy-duty protection. Over-packaging drives up material and freight costs. Buyers should focus on: Identifying SKUs most vulnerable to damage. Applying protective features only where necessary. Leveraging data from past returns to guide improvements. Holiday Packaging Solutions with Brown Packaging Brown Packaging helps brands design e-commerce packaging that survives peak season conditions without unnecessary cost. From reinforced corrugated boxes to protective inserts and coatings, our solutions ensure your products arrive intact and customer-ready. Contact us to prepare your packaging program for the holiday rush. References ASTM International. (2023). ASTM D4169: Standard Practice for Performance Testing of Shipping Containers and Systems.Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.International Safe Transit Association (ISTA). (2022). ISTA Series Test Procedures for Packaged Products in Transit. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Ecommerce Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts