Export Packaging for Injection Molded Parts
Scratches and transit damage are the most common reason a moulded part is rejected on arrival, and almost all of it is decided before the box is sealed. We design the separation, the carton strength, the pallet pattern and the moisture protection around your part, your freight route and your carton count, then pack in the same building where the parts are moulded.
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ESD / EPE / Blister
Packing Options
ISTA 1A / 3A
Drop Test Protocol
ISPM 15 Marked
Pallet Compliance
Materials
| Grade | Properties | Typical Applications |
|---|---|---|
| Corrugated Carton (Single Wall, B or C Flute) | 3 ply board made of one liner, one flute and one liner, typical 3 to 4 mm thickness, edge crush rating around 32 ECT, keeps its own weight low which matters when freight is charged on volume | Standard export cartons for non-fragile parts, inner cartons inside a master carton, air freight where carton weight is part of the chargeable weight |
| Corrugated Carton (Double Wall, BC Flute) | 5 ply board, 6 to 9 mm thickness, edge crush rating around 44 ECT or higher, holds its compression strength through a humid sea voyage far better than single wall | Heavy parts, master cartons, cartons stacked five or more layers high, shipments going through hot and humid routes |
| EPE Foam (Expanded Polyethylene) | Closed cell foam at 15 to 30 kg per cubic metre density, die cut to the part shape, recoverable after compression, chemically inert and does not dust | Layer pads between stacked cosmetic parts, die cut surrounds for irregular shapes, edge protection inside a carton |
| ESD Anti-Static Bag and Film | Surface resistivity in the range of 10 to the power 9 to 10 to the power 11 ohms per square, dissipative rather than conductive, pink polyethylene or metallised barrier grade for moisture sensitive assemblies | Electronic housings with metal inserts, connector bodies, parts going into a static controlled assembly line |
| Blister Tray and Clamshell (PET or PVC) | Thermoformed to the part outline so each piece sits in a fixed position, transparent for visual counting, rigid enough to carry a stack load | Retail ready parts, small components that would tangle in bulk, automated line feeding at the destination |
| VCI Paper and Stretch Film | Volatile corrosion inhibitor treated material that protects metal inserts and metalised surfaces during a humid voyage without leaving a residue | Insert moulded parts with exposed steel, threads and machined faces, anywhere a salt laden sea voyage would rust a bare insert |
Process Parameters
| Parameter | Standard Range |
|---|---|
| Carton Board Grade | Single wall 32 ECT to double wall 44 ECT and above, selected on stack height and part weight |
| Part Separation Method | EPE layer pad, die cut foam surround, blister tray, individual poly bag, paper interleaving |
| Antistatic Protection | Surface resistivity 10^9 to 10^11 ohm per square, metallised barrier film on request |
| Drop Test Reference | ISTA 1A for cartons under 68 kg, ISTA 3A for individual parcel shipments |
| Drop Height (ISTA 1A, by carton weight) | 760 mm under 9.5 kg, 610 mm to 18.6 kg, 460 mm to 27.7 kg, 305 mm to 45.4 kg, 200 mm to 68 kg |
| Desiccant Calculation | Per MIL-D-3464, one unit per 0.42 cubic metre of enclosed volume, adjusted for voyage length |
| Pallet Specification | Heat treated to ISPM 15 with the IPPC mark stamped on two opposite faces |
| Pallet Footprint | 1200 x 1000 mm, 1200 x 800 mm, 1100 x 1100 mm, matched to your destination handling system |
| Pallet Stack Height | Up to 1600 mm including pallet for most forwarders, lower when airline limits apply |
| Container Reference | 20GP around 33 cubic metre nominal, 40HQ around 67 cubic metre nominal, usable volume depends on the pallet pattern |
Surface Finishes
Individual Poly Bagging
Every part goes into its own bag before it enters the carton. For glossy or high polish cosmetic parts this is the cheapest way to stop the parts rubbing against each other in transit, and it costs a fraction of what a returned shipment does. Bag thickness and closure type are chosen to match whether the destination unpacks by hand or by machine.
EPE Layer Pads and Die Cut Surrounds
Foam pads between layers stop stacked parts touching, and die cut surrounds hold each part in a fixed position so nothing shifts when the carton is handled sideways. For a cosmetic housing this is usually the difference between a clean arrival and a pallet of scuffed rejects, because most transit damage comes from vibration against a hard neighbour rather than from a single impact.
Blister Tray Packing
A thermoformed tray holds each part in a defined pocket, which both protects the cosmetic surface and lets your receiving team count at a glance. It suits small components, assemblies going to a line side, and retail packs. The tray tooling is modest and is quoted separately from the injection tool.
ESD and Moisture Barrier Sealing
Static dissipative bags, and where required a metallised barrier film sealed with a desiccant pack inside, protect electronics housings and metal inserted parts. The barrier film is heat sealed rather than folded, because a folded closure is not a moisture seal and will fail halfway through a humid voyage.
Carton Sealing and Strapping
Cartons are taped in an H pattern with the top and bottom seams covered, then the pallet is stretch wrapped and strapped with PET strap over the corners. The combination of wrap and strap keeps the load square through container handling, where the dominant failure mode is a shifted top layer rather than a broken carton.
Shipping Marks and Label Placement
Carton marks are printed or labelled on two adjacent faces so one is always readable when stacked, and pallet labels are placed on two opposite faces. Contents, quantity, carton number within the total, net and gross weight, country of origin and any handling symbols are standard, and we can print customer or marketplace labels from your artwork.
Design for Manufacturing (DFM)
- Tell us the cosmetic surfaces before the packing design starts, because covering every face in foam costs more than covering only the faces a customer will see
- Decide whether the part can nest or must be separated, because nesting cuts carton volume directly and usually costs less than any other change you can make
- Set the carton count to divide cleanly into your pallet pattern, since a carton that leaves a half filled layer wastes more freight than any saving elsewhere
- Check whether the destination requires a specific label size or barcode, because relabelling on arrival is charged by the carton and removes any saving from cheap packing
- Specify whether the part carries metal inserts, because an exposed insert needs rust protection that adds material cost and is far cheaper than reclaiming rusted stock
- Ask for antistatic packing if the part goes into an electronics assembly line, since static damage often shows up as a field failure rather than as visible damage
- Measure the carton, not the part, when you estimate freight, because freight is charged on the greater of weight and volume and a bulky pack can double the cost
- Plan the moisture protection around the actual voyage length and season, since a short dry route needs very little desiccant and a monsoon route needs meaningfully more
- Agree the drop test reference before the first shipment, so the standard is settled while it is still a drawing rather than a dispute
- Upload STEP, IGES or DXF files and get a free packing proposal within 24h covering separation method, carton size, pallet pattern and container count
Tooling & Capacity
| Type | Lead Time | Suitable For |
|---|---|---|
| Packing Only (Existing tool or hand pack) | 1 week for pack design and first article | Any volume, standard cartons and stock EPE shapes, lowest cost where the part tolerates bulk packing |
| Die Cut EPE Tooling | 1 to 2 weeks | Repeat programs and fragile or cosmetic parts, where a shaped insert removes the labour of hand wrapping every piece |
| Thermoformed Blister Tooling | 2 to 3 weeks | Retail presentation, line side feeding, small parts that must stay separated and countable |
| Combined Programme (Moulding plus Packing) | 2 to 3 weeks aluminium soft tool, 4 to 6 weeks steel production tool, pack design runs in parallel | Programmes where tooling, trials and packing are quoted together on one purchase order |
Quality Assurance
- Cosmetic surfaces inspected before packing under the agreed lighting and viewing distance, against the approved sample
- Carton count verified twice, once at packing and once at pallet completion, with the count recorded per pallet
- Carton drop and stack verification arranged at a third-party laboratory to ISTA 1A or ISTA 3A on request
- Moisture indicator card included in sealed barrier packs so the buyer can see whether the seal held through the voyage
- Pallet and carton check confirming the ISPM 15 heat treatment mark is present and legible on every pallet
- Weight and dimension record per carton and per pallet, issued before loading so forwarder documents match physically
- Photographic record of the packing method, pallet pattern and closed container, sent before vessel departure
- Packing list and Certificate of Origin issued with every shipment, additional trade documents as your route requires
- Third-party inspection by SGS, Bureau Veritas or TUV arranged at any stage on request, including pre-loading checks
- Any deviation from the agreed pack method is reported before shipment rather than discovered on arrival
Applications
- Consumer electronics housings with a cosmetic outer face
- Appliance panels and control bezels shipped as spares
- Automotive interior trim going to a line side assembly plant
- Packaging closures and container bodies exported in bulk
- LED housings and lens covers where scratching shows in use
- Connector bodies and terminal blocks packed for automated feeding
- Retail ready blistered product
- Industrial plastic components shipped with metal inserts
- Spare and service parts distributed across several destinations
Why Choose FHY Precision
Packing designed and applied in the same building as the moulding, so the method can be tested on real parts before the first shipment
Separation method chosen from your cosmetic requirement and your freight route rather than from whatever foam is in stock
Carton size and pallet pattern set together, so the container fills properly and freight per piece is predictable
Moisture and static protection calculated rather than guessed, including desiccant quantity and bag grade
Certificates, packing lists and Certificate of Origin issued with every lot, alongside photos of the closed container
Third-party inspection by SGS, Bureau Veritas or TUV available at any stage, with EN 10204 3.1 material documentation on request
Packed at our China plant at factory-direct pricing, nothing between you and the press
One purchase order covers moulding, packing design, packing labour and documentation
FAQ
1. Why do moulded parts arrive scratched when they left the factory clean?
Almost always because they rubbed against each other in transit. A carton of parts in a container is vibrated for weeks, and any two hard surfaces touching will polish each other. The fix is separation, either individual bags, layer pads, or a blister tray, chosen by how visible the cosmetic face is. This costs less than most buyers expect because the labour saved downstream is significant.
2. How do I choose between individual bags and a blister tray?
Bags are cheaper per piece and faster to set up, and they are the right answer for bulky parts that are not cosmetic. Blister trays cost more per pocket but they hold position, let you count at a glance and feed directly into an automated line. If your receiving team unpacks by hand into a bin, bags win. If the pack goes to a line side or straight onto a retail shelf, the tray usually pays for itself.
3. What does a drop test actually tell me?
It tells you whether the pack survives the handling it will realistically receive, and it gives you a number to settle disputes against. ISTA 1A drops a carton ten times from heights set by carton weight, and the drop heights reduce as the carton gets heavier because heavy cartons are handled differently. A pack that passes tells you the separation and board grade are adequate, not that the contents are indestructible.
4. Do you charge for packing as a separate line item?
Yes, and we prefer it that way. Packing labour and materials are listed separately from the moulded piece price so you can see exactly what each option costs and change it without renegotiating the part. Stock cartons and simple bagging can sometimes be absorbed into the piece price for very high volumes, but a separate line keeps the comparison honest.
5. How much desiccant does a carton actually need?
Work from the enclosed volume rather than the number of parts. The MIL-D-3464 method gives one unit per 0.42 cubic metre of sealed volume, then we add margin for voyage length and season. A short container route in a dry month needs very little, while a monsoon season voyage through a humid port needs noticeably more. We show the calculation so you can audit it.
6. What is the IPPC or ISPM 15 mark and why does it matter?
It is the stamp showing the wooden pallet or crate has been heat treated to kill pests, which most countries require for untreated wood packaging. We use heat treated pallets carrying the mark stamped on two opposite faces, so customs has something legible to check. Without it, a shipment can be refused entry or fumigated at your cost and delay, which is expensive relative to the pallet itself.
7. Can you ship to an Amazon or fulfilment warehouse with their labels?
Yes. Send the label artwork and the packing specification, and we apply the carton and pallet labels as required, including the carton number within the total and the destination specific placement rules. It is worth telling us the destination warehouse at quote stage, because some networks have requirements on carton weight ceilings or pallet height that change how we build the pack.
8. What happens if my part is too heavy for a standard carton?
We move to a heavier board grade and usually to a smaller carton, because the relationship between weight and drop height means a heavy carton is handled more gently but has higher compression load on the bottom layer. Practically this often means two smaller cartons rather than one large one, which spreads the load on the pallet and usually reduces damage more than it increases cost.
9. Do you photograph shipments before loading?
Yes, standard practice. You get photographs of the packing method on the first carton, the completed pallet pattern, and the container after loading and before the doors close. It is a small thing that settles later questions about count and condition, particularly for a first shipment from a new supplier where nobody has yet seen how the pack behaves.
10. Can you combine parts from several orders in one container?
Yes, consolidation is common and it saves real freight. Send the list of part numbers and quantities per destination, and we will work out whether the container fills on volume or on weight first, because that determines whether consolidating helps. When multiple customers ship together we keep the pallets physically separated and label each block clearly so unloading is simple.
11. What documents come with a shipment?
A packing list with per carton contents and weights, a commercial invoice, and a Certificate of Origin. Where your route needs a preferential origin form for a trade agreement, tell us at quote stage because those are applied for before loading rather than after. Mill test reports and resin certificates tied to the production lot are available on request.
12. Do you provide ESD packing for electronic parts?
Yes. Static dissipative bags in the 10 to the power 9 to 10 to the power 11 ohm per square range are standard, and for moisture sensitive assemblies we use a sealed metallised barrier film with a desiccant pack and humidity indicator inside. A folded bag closure is not a moisture seal, so anything relying on desiccant gets heat sealed rather than taped shut.
13. How early should packing be discussed?
Before the tool is cut, ideally. Two reasons: the part can be designed to nest or stack in a way that directly cuts carton volume, and gate or ejector marks can be placed away from faces that cannot be protected cheaply. Both are free changes at design stage and both cost money once steel is cut.
14. Can you pack to our existing specification?
Yes, and many customers have one. Send the specification document and we will quote to it, flag anything that is not practical in our plant, and quote the alternative side by side. Where a specification is stricter than the part actually needs we will say so with the cost difference shown, and where it is not strict enough we will tell you what we expect to fail.
15. What is included in the packing proposal you return in 24 hours?
A recommended separation method with reasoning, the carton size and board grade, the desiccant quantity calculation if moisture protection applies, the pallet footprint and layer count, and the resulting container count for your quantity. If you send a target landed cost per part we will work back from it and show where the pack can be simplified.
16. Do you arrange third-party inspection of the packing itself?
Yes. SGS, Bureau Veritas or TUV can attend packing, verify carton counts, witness the drop test at a laboratory, and check pallets before loading. For a first shipment from a new supplier this is usually worth doing once, because it settles the standard for every shipment after it and the cost is small compared with the value of the goods.