How to Reduce Product Damages in Transit: Tips for Retail & Wholesale Freight

Shipping damage is a silent profit killer. Globally, damaged items make up about 20% of e-commerce returns, driving billions in hidden costs. In Australia alone, damaged or stolen parcels cause losses of around A$224 million each year

Shipping damage isn’t just about customer complaints. It chips away at margins, damages your brand, and forces you to absorb repackaging and costs of handling returns. With the right packaging, planning, and courier partner, most of these losses can be prevented.

How to Reduce Shipping Damage

In Australia, distances and handling can put your products at risk. The best way to reduce damage is through solid preparation.

A few simple steps to prevent product damage during shipping and freight handling in Australia:

• Use strong boxes: Double-walled cartons protect against crushing and punctures.
• Add protective padding: Bubble wrap, foam, or airbags stop items from shifting and breaking.
• Secure big shipments: Palletise, strap, or shrink wrap to keep loads stable.
• Label clearly: Mark boxes “fragile” or “this way up” so they’re handled with care.
• Pick the right courier: Work with carriers experienced in your freight type.
• Insure valuable items: Freight insurance protects your business if something goes wrong.
• Track every shipment: Keep records, photos, and use real-time tracking to monitor deliveries.

Couriers & Freight simplifies this process with reliable courier options, expert packaging advice, and comprehensive insurance support.

Protect Your Goods from Shipping Damage

Keep every shipment safe with expert packing advice, reliable couriers, and freight insurance from Couriers & Freight.

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Common Causes of Product Damage in Transit

Even with the best preparation, damage can still occur if key factors are overlooked. Below are the most common causes of shipping damage during handling and delivery.

Poor Packaging Materials

Using thin, worn, or poorly constructed boxes leaves products unprotected during transit. Fragile items such as glassware, ceramics, and electronics are especially vulnerable. Without adequate padding, items shift inside boxes and often break. Research shows that nearly half of all reported shipping damage stems from poor packaging, while mishandling makes up most of the rest.

Mishandling During Transit

Rough loading, improper stacking, and careless handling are leading causes of freight damage. Heavy boxes placed on lighter ones can crush contents, while forklifts or conveyor systems can damage even well-packed items if handled incorrectly.

Inadequate Labelling

Parcels without clear labels like “fragile” or “this way up” are more likely to be dropped or stored upside down. Clear labelling helps couriers identify sensitive or temperature-controlled items, reducing handling risks.

Environmental Factors

Exposure to extreme heat, humidity, rain, or cold can weaken packaging and spoil goods. Cardboard softens when wet, chocolate melts, and electronics can short-circuit. Perishable items and temperature-sensitive freight need climate-controlled options to stay safe in transit. If damage does occur despite precautions, freight insurance can help cover your losses.

7 Practical Ways to Prevent Shipping Damage

Preventing shipping damage doesn’t always mean spending more. It’s about making smarter choices in how you pack, handle, and ship your goods. Here are seven proven ways to keep your products safe and your customers satisfied.

1. Use Strong, Double-Walled Boxes

Choose double-walled or reinforced corrugated boxes that can handle stacking, impact, and rough handling. For heavy or awkwardly shaped products, custom-sized boxes minimise empty space and prevent items from shifting in transit.

2. Add Protective Padding

Wrap each item separately using bubble wrap, foam inserts, or air cushions for maximum protection. Keep fragile pieces from touching each other inside the box. Good cushioning absorbs shocks and helps prevent shipping damage caused by sudden drops or vibrations.

3. Palletise and Secure Large Shipments

Palletise large loads to maintain stability. Secure boxes tightly with shrink wrap or straps, distribute weight evenly, and always place fragile items on top. Always place fragile items on top, not the bottom.

4. Label Fragile and Handle-With-Care Items Clearly

Use large, visible labels that read “fragile,” “handle with care,” or “this way up.” Include orientation arrows and temperature warnings if needed. Proper labelling helps warehouse and courier teams handle goods more carefully.

5. Choose the Right Courier for Your Freight Type

Choose a courier with experience in your freight type. For sensitive or bulky shipments, specialist couriers reduce breakage risk through expert handling. Consider Couriers & Freight’s Parcel Express for reliable, damage-minimised delivery.

6. Insure High-Value Shipments

Freight insurance protects your business from financial loss if goods are damaged in transit. Insure high-value or fragile products such as electronics, glassware, or jewellery. 

Learn more in our guide to Freight Insurance in Australia.

7. Document and Track Shipments Properly

Maintain clear records and track every shipment in real time. Photograph items before dispatch and record their condition. If damage occurs, file a product damage report promptly to support your insurance claim and improve future packing practices.

Who Is Responsible for Shipping Damage?

Even with careful preparation, damage can still occur. Knowing who’s responsible under Australian Consumer Law (ACL) helps resolve claims quickly and fairly. In most cases, responsibility depends on the cause of the damage and when it occurred.

Here’s how it generally breaks down:

Sender Responsibility

If goods are packed poorly, with weak boxes or insufficient padding, the sender is liable for any resulting damage.

Courier Responsibility

If items are damaged due to rough handling, improper stacking, or mishandling during transit, the courier is usually responsible.

Customer Responsibility

If the customer provides an incorrect or incomplete delivery address, they may be liable for resulting delays or losses.

Shared Responsibility

Sometimes, liability is shared. For example, when the packaging meets standards, but the courier still mishandles the parcel.

Protect your business by documenting packaging, photographing goods before dispatch, and keeping signed delivery records. Couriers typically have claims forms or product damage reports to help resolve disputes efficiently. Customers should report visible damage at the time of delivery to confirm accountability.

Businesses can refer to the NSW Government Consumer Rights for more details on repairs, replacements, and refunds. Combining proper packaging with Freight Insurance in Australia provides extra protection and peace of mind against unexpected shipping damage.

What to Do If Your Goods Arrive Damaged

Even with careful packing and trusted couriers, shipping damage can still occur. What matters most is how quickly you respond. Acting fast protects your business, supports your claim, and maintains customer trust.

Follow these steps:

1. Inspect goods immediately: Open the parcel as soon as it’s delivered and check every item carefully. Note any dents, tears, or broken pieces. Even small defects can affect your claim.
2. Take photos and record details: Document the condition of the packaging and contents before moving or unpacking items. Clear evidence makes your claim easier to verify.
3. File a damage report with your courier: Submit photos, delivery notes, and shipment details through the courier’s official claims process. The sooner it’s filed, the faster the resolution.
4. Contact your courier or freight partner for assistance: Reach out to your provider for help with next steps. Couriers & Freight can guide you through the claims process, assist with recovery, and advise on how to prevent future issues.

Acting quickly minimises losses, preserves customer trust, and helps improve how future shipments are packed and managed.

Preventing Shipping Damage Starts with Preparation

Reducing shipping damage starts with good preparation. Strong packaging, clear labelling, and choosing the right courier all work together to keep your products safe in transit.

Couriers & Freight supports Australian businesses with reliable transport solutions, freight insurance, and practical packing advice to help you deliver every shipment with confidence.

Protect Your Goods from Shipping Damage

Keep every shipment safe with expert packing advice, reliable couriers, and freight insurance from Couriers & Freight.

Get a Quote Now