Common Packing Mistakes and How to Avoid Them

Using the Wrong Adhesives and Sealants

One of the most common packing mistakes is using the wrong type of tape or not sealing boxes properly. If a box isn’t sealed well, it can pop open during shipping, leading to damaged or lost products. Many times, teams rush through packing or use low-quality tape that doesn’t hold up under stress.

To avoid this, make sure you’re using the right adhesives for the job. A strong packing tape or industrial hot-melt adhesive works best for securing cartons. A good rule of thumb is to use the H-taping method—applying tape along the center seam and both edges—to keep boxes securely closed. Also, match the adhesive to the type of shipment. For example, water-activated tape is great for humid conditions, while hot-melt glue is better for heavy-duty packaging.

Simple fixes for better seals:

• Choose high quality tape that's strong enough for your packaging needs.
• Use the H-taping method to reinforce seams and prevent boxes from opening.
• Pick the right adhesive based on the shipping conditions.
• Check out Brexia's selection of Adhesives & Sealants to get the best materials for the job.

Poor Material Handling Practices

Even if your packaging is perfect, poor material handling can ruin your hard work. Overloading pallets, stacking boxes unevenly, or using damaged pallets can lead to product damage, safety hazards, and unnecessary delays. If a pallet is too heavy or stacked incorrectly, it might collapse, creating a mess and putting workers at risk.

To avoid these issues, make sure pallets are inspected for damage before use, and never exceed their weight capacity. Stacking boxes evenly and wrapping them with stretch film can help keep loads secure. Also, use the right equipment—pallet jacks and forklifts can prevent injuries and make handling much smoother.

Tips for safer and smarter handling:

• Avoid overloading pallets, distribute weight evenly.
• Inspect pallets before use and replace damaged ones.
• Stack boxes properly and use shrink wrap for extra security.
• Use the right tools, Brexia offers Material Handling solutions like pallet jacks and dollies to make the job easier and safer.

Ignoring Safety Measures

Skipping safety precautions might save time in the short term, but it can lead to serious accidents. Common mistakes include not wearing gloves when handling sharp materials, ignoring proper lifting techniques, and failing to mark forklift pathways.

Making safety a priority is key to keeping operations running smoothly. Simple changes—like requiring workers to wear gloves, using high-visibility vests, and keeping walkways clear—can make a big difference. Regular training sessions on lifting techniques and emergency procedures are also a must.

Quick safety fixes:

• Provide proper PPE, gloves, safety glasses, and vests should be standard.
• Set up ergonomic workstations to reduce strain on workers.
• Keep aisles clear and mark walkways to prevent accidents.
• Invest in quality safety gear, Brexia offers a range of Safety Equipment to keep your team protected.

​

Using Inefficient Packaging Solutions

Another mistake is using boxes that are too big or too small for the product. Oversized boxes allow products to shift during transport, increasing the risk of damage. On the other hand, overstuffed boxes can burst open under pressure. Not using enough cushioning materials—like bubble wrap or foam—can also lead to breakage.

The key is to choose packaging that fits the product properly and provides the right amount of protection. Using sturdy boxes, adding internal padding, and testing packaging for durability can help reduce damages and shipping costs.

How to improve packaging:

• Pick the right size box to avoid wasted space and product movement.
• Use enough cushioning to protect fragile items.
• Test packaging durability before shipping.
• Check out Brexia's Packaging Solutions to find stretch films, shrink wraps, and other protective materials. 

​

Packing may seem like a routine task, but small mistakes can have a big impact on efficiency and costs. By using the right adhesives, handling materials properly, prioritizing safety, and choosing the best packaging, manufacturers can reduce damage, improve productivity, and keep shipments on track.

With the right approach—and Brexia’s high-quality adhesives, handling equipment, safety gear, and packaging solutions—packing can go from a weak link to a competitive advantage. Let’s make every shipment a smooth and successful one!

Learn More