Hey there, Other Products
If you’re anything like me, you’ve probably spent way too much time stressing over products getting beat up before they even reach their final destination. Last month, I had a client call me panicking because a batch of their custom small hardware parts—you know, the tiny stuff that holds everything together—showed up with 12% of them scuffed and dented. They were using standard cardboard inserts and foam packing, the kind you pick up at any big box store, and it just wasn’t cutting it. That’s when I started asking myself (and my team, who deals with this stuff every single day): Are there other products out there that are actually more resistant to damage—way more than what most people are reaching for? And as someone who’s been in the “other products” supply game for 8 years, I’ve dug into this deep enough to share what’s actually worth your time, and what’s just hype.
First off, let’s get one thing straight: most people default to the same old packing and protection without thinking about why something fails. Take that foam my client used, for example. It’s the generic polystyrene foam—you know, the white stuff that crumbles if you look at it wrong. If you’re shipping something that has hard edges, or even just weight that shifts during a 3-day truck ride, that foam doesn’t give consistent protection. It compresses in one spot, leaving a gap, and then the product slams around. I’ve seen it happen with everything from phone parts to gardening tools. But here’s the thing I learned last year when we tested new materials: not all “protective products” are made equal. There’s a whole category of stuff that’s flying under the radar because people are stuck in their old ways, and it’s game-changing for damage prevention.
Let’s start with the ones we’ve been testing nonstop in our warehouse over the past year: cross-linked polyethylene (XLPE) foam. Wait, I know what you’re thinking—“isn’t that just another foam?” No, hear me out. Regular polystyrene (EPS) foam is made by expanding beads with gas, so it has all these little air pockets that can pop or collapse. XLPE foam is made by cross-linking the polymer chains with radiation, so those pockets are closed-cell and way more durable. We did a test a few months back: we packed two identical sets of precision metal brackets—one with EPS, one with XLPE—shipped them cross-country via standard LTL freight, and then inspected them. The EPS set had 9 dented brackets, 2 with scratches deep enough to affect their function. The XLPE set? ZERO damage. Not a single scratch, not a bend. And here’s the kicker: it’s not just for small parts. We’ve used it for medium-sized items like portable power tools too, and it holds up against vibrations way better than that thin bubble wrap everyone loves. Bubble wrap’s great for light stuff, but if you’re shipping something over 5 pounds, it just doesn’t have the cushioning to keep it from moving. XLPE is more expensive upfront, but when you calculate the cost of replacing damaged products, it’s a no-brainer. My client from the hardware business? We switched them over to custom-cut XLPE inserts, and their damage rate dropped to less than 1% last quarter. They saved enough in replacement fees to cover the new materials twice over.
But wait, XLPE isn’t the only secret weapon. There’s also corrugated plastic—sometimes called polypropylene (PP) corrugated, or “coroplast” if you want the brand name. A lot of people confuse it with regular cardboard, but cardboard soaks up moisture like a sponge, especially if it’s going through a rainy distribution center. I’ve had a shipment get stuck in a storm last spring, and by the time it arrived, the cardboard boxes were soft and the products inside were ruined. Corrugated plastic is waterproof, first off. It’s also way more rigid than cardboard, but still lightweight. We use it for custom dividers in bulk shipping boxes now, and it’s been a game-changer for clients who ship things like glassware, ceramic mugs, or even small electronics. One of our clients sells custom coffee mugs, and they were getting 15% returns for broken mugs until they swapped their cardboard dividers for corrugated plastic ones. Now their return rate is under 2%, and they’ve cut down on waste because corrugated plastic can be reused for multiple shipments. The only downside? It’s a little thicker than cardboard, but most clients don’t mind because it saves them money long-term. Plus, it’s recyclable, which is a huge plus for businesses that are trying to be more eco-friendly.
Now, let’s talk about something that’s not even packing material—wait, I know, the question is about “products” overall, not just packing, right? The original question is “are there other products that are more resistant to damage,” so this applies to the actual items you’re shipping, too. A lot of small business owners I talk to don’t think about choosing a product that’s durable in the first place, they just use whatever is cheapest. For example, if you sell garden trowels, don’t go for the thin steel ones that bend if you drop them. Get trowels made from forged steel, with a reinforced grip. We supply both types, and I can tell you that the number of complaints we get about the thin trowels is through the roof, while the forged ones have a 1% damage rate max. It’s the same with things like storage bins: plastic bins made from HDPE (high-density polyethylene) are way more resistant to cracks and dents than the thin PET plastic ones that break if you set something heavy on them. I had a client who sold storage bins, and they switched from PET to HDPE last year, and their customer complaints dropped by 70%. People don’t just care about damage during shipping—they care about damage once they get the product, too. That’s why choosing a more resilient base product is just as important as choosing good packing.
Wait, but let’s not forget about the “in-between” stuff—products that are designed for protection, but not the foam or corrugated kind. Like, what about those edge protectors made from high-impact PVC? A lot of people overlook edges, but that’s where 30% of product damage happens, especially with rectangular or angular items. If you’re shipping a wooden table, a metal shelf, or even a large artwork, the corners are the first thing to get banged up when it’s being loaded or unloaded from a truck. We used to just wrap the corners in extra bubble wrap, but now we supply these rigid PVC edge protectors that slide right on, and they hold up against bumps that would have scuffed a table before. One of our clients does custom furniture, and they started using these edge protectors last year, and their damage claims for corner scuffs dropped by 85%. They even started reusing the edge protectors for return shipments, which saves them even more money. It’s a small product, but it makes a huge difference.
I’ve also learned a lot from working with clients across different industries over the years. For example, the tech startup that ships portable Bluetooth speakers—they were using standard plastic blister packs, but those would crack if the speaker was jostled. We switched them to custom-molded EVA (ethylene vinyl acetate) inserts, which are a soft, flexible foam that’s way more durable than the blister packs. EVA is also shock-absorbent, so it cushions the speaker against vibrations, and it doesn’t scratch the finish like some hard plastics do. Their damage rate went from 10% to less than 2% after that switch. Another client is a food distributor that ships small kitchen appliances—they were using cardboard boxes with paper liners, but the liners would get wet from condensation inside the truck, causing the appliances to rust. We suggested they use waterproof EVA liners, and that fixed the condensation issue completely.
But here’s the thing I want to make clear: none of these products are one-size-fits-all. You can’t just go out and buy XLPE foam for everything, because it might be overkill for a tiny item like a keychain, and it would cost more than necessary. You have to match the product to what you’re shipping, and to the conditions it’s going to face. For example, if you’re shipping something small and light, like jewelry or phone accessories, a thin layer of EVA or even high-quality bubble wrap might be enough. But if you’re shipping something heavy, with hard edges, that’s going on a long cross-country trip, you need something like XLPE foam or corrugated plastic to hold up. The mistake a lot of people make is using the same packing for every product, regardless of size, weight, or fragility.
I’ve had so many clients tell me they tried “more resistant” products before, but they got scammed by cheap knockoffs. That’s another thing to watch out for. Not all XLPE foam is the same—some manufacturers cut corners by using less cross-linking, so the foam is just as soft and crumbly as EPS. Same with corrugated plastic: there’s thin, flimsy stuff that bends if you look at it, and there’s thick, rigid stuff that holds up to heavy loads. That’s why it’s important to work with a supplier that tests their products, not just sells whatever is cheapest. I’ve been in this industry long enough to tell the difference between quality and garbage, and I make sure every product we supply is tested under real-world conditions, not just lab tests.
Now, let’s circle back to the original question: Are there other products that are more resistant to damage? Absolutely. The problem is that most people don’t know about them, because they’re used to the same old options from the big box stores. You don’t have to settle for products or packing that only does a mediocre job of protecting what you ship. Whether it’s custom foam inserts, rigid edge protectors, waterproof corrugated plastic, or even a more durable base product, there are options out there that will cut your damage way down, save you money in the long run, and keep your customers happy.
I get it, it can be overwhelming to switch things up when you’ve been doing them the same way for years. But trust me, I’ve seen the numbers. My clients who have made the switch to these more resistant products have seen their damage rates drop by as much as 80%, and their customer satisfaction scores go up because they’re not getting broken items. If you’re tired of losing money to damaged products, or dealing with frustrated customers because their order arrived banged up, it might be time to take a look at what else is out there.
We’ve spent years testing and refining all these products, and we can help you figure out exactly what works for your specific needs. No generic solutions, no one-size-fits-all garbage—just products that actually do what they’re supposed to do: protect your stuff. If you want to chat about your shipping pain points, or learn more about the products we supply that are designed to resist damage, feel free to reach out. We can send you samples, walk through what works best for your products, and help you cut down on that damage rate that’s been eating into your profits. Don’t keep settling for products that let you down—let’s find something that actually works for you.
Embossing Roller References:
- Packaging Digest. "Cross-Linked Polyethylene Foam: The Durable Choice for Fragile Goods." 2023.
- Corrugated Plastics Association. "Benefits of Corrugated Plastic Packaging for Shipping & Storage." 2022.
- American Society for Testing and Materials (ASTM). "Standard Test Method for Impact Resistance of Packaging Materials." ASTM D4169-21, 2021.
- National Restaurant Association. "Durable Packaging Solutions for Food Service Shipping." 2023.
Kunshan Hanhan Co., Ltd.
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