Collapsed packaging

Excess moisture causes irreversible damage to packaging boxes.

Shipping boxes are typically made from paper-based materials that are hygroscopic, meaning they will absorb moisture. This severely affects a box’s structural integrity and strength, which can lead to the collapse of the packaging and the loss of valuable cargo as well as costly disruption to the supply chain.

Understanding why packaging collapses

1. Moisture beats cardboard

Studies of corrugated cardboard and its compressive strength clearly show that the material is very sensitive to environmental conditions – and especially high relative humidity (RH). The paper fibers that make up the material are hygroscopic, meaning they absorb moisture. This changes the dimensions of these fibers, which translates into changes in a box’s overall structure and a loss of strength.

The table below shows how boxes may lose up to  30–40% of their compression strength at 70% RH.

Relative humidity

Approx. Strength retention

50% (standard) 100%
60% ~90–93%
70% ~60–70%

2. Ocean-going shipping dramatically increases the risk

When describing the strength and resilience of their box materials, packaging manufacturers typically use a standard testing environment of 50% relative humidity and 23° C. Clearly, this does not reflect the conditions for boxes in ocean-going containers where temperature fluctuations and resulting humidity spikes will almost always push far beyond those levels. Boxes also lose their strength dramatically over time, which will be a feature of long-distance transport, not to mention any storage before or after shipping.

3. Choosing the right packaging materials and dimensions is difficult

To lessen the risk of collapse, companies often look to use stronger, more heavy-duty materials and dimensioning. This often means using higher-quality fresh fibers instead of less resilient recycled fibers and/or by over-dimensioning with thicker wall structures that use more materials.

While usually effective in lowering the risk of collapse, these measures add significantly to the cost and weight of packaging as well as increasing the burden on the environment. Even then, the strongest materials and construction for the standard conditions of 23 °C and 50% RH could prove to be the weakest for long-term performance.

Different ways to prevent collapsed packaging

Higher-quality materials and heavier-duty dimensioning

As mentioned, using fresh virgin fibers and/or stronger, heavier paper increases the strength of a box and lowers the risk of collapse through moisture damage. The paper can also be coated with water-resistant substances. However, these add to the cost and environmental impact of each shipment while still exposing you and your cargo to unnecessary risk.

Optimized packaging solution

Many packaging suppliers will look at the whole journey and storage of the cargo to understand the full performance needs. In such cases, these suppliers will look at performance well outside the standard conditions, for instance showing how boxes perform at 90% RH over a 10-day period. Other solutions can involve plastic boxes or plastic wrapping to try and avoid the moisture problem altogether, however these measures aren’t always practical logistically and they invariably cost more and are less sustainable.

Combined packaging and desiccant solution

Combine your packaging choice with the right moisture protection strategy that uses desiccants to control and maintain the relative humidity in the container. You can choose your packaging with more accuracy and confidence knowing the conditions it will be coping with. And, as a result, you can even reduce the size and weight of the packaging as well as move towards a higher percentage of recycled fibers.

Meeting the new PPWR regulations

Using desiccants as part of a combined solution would also help manufacturers and shippers meet the new EU Packaging and Packaging Waste Regulation (PPWR) that has recently come into effect. The stricter PPWR regulations are designed to reduce the growing volume of packaging waste and will force changes in how companies set up their packaging.

Effective and reliable moisture protection using desiccants will make it easier to meet the targets and requirements such as:

  • Recyclability: All packaging, including cardboard, must be recyclable by 2030, with design for recycling criteria becoming even stricter by 2035. This means that cardboard packaging must be easily separable and free from materials such as a mix layer of plastic that hinder recycling. This plastic layer can be avoided with desiccants.
  • Minimum Recycled Content: While the main target for recycling is plastic, encouraging the use of recycled fibers is in line with circular economy goals. Recycled fibers are more sensitive to high relative humidity – but the change can be made if customers use desiccants.

Our solution

Learn more about AbsorGel® and our moisture damage prevention line of desiccants:

Container desiccant / Inbox desiccants

To get the right moisture protection that is fully optimized for your cargo and choice of packaging, speak to us. Our Peace of Moisture Mind® (POMM) approach can securely protect your cargo and boxes against moisture damage – as well as delivering the most cost-effective, sustainable and PPWR-compliant solution.

More information on POMM here

Customer example

Using desiccants to maintain RH at below 60% provided great value for one customer:

  • Safe shift from heavy to light single-wall board
  • Material savings of ~166 kg
  • Estimated cost savings of €130–€165 per shipment
  • Lower CO₂ emissions due to reduced material usage
  • Improved stacking safety and reduced packaging failure risk = fewer damaged goods and returns
  • Facilitates switch to 30% post-consumer recycled content

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