Improving Napkin Packaging to Prevent Faults for Retail Programs
How we identified the root cause of collapsed POD packaging during transit and strengthened packaging and container loading.
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Key Highlights
1) Investigated the root cause of damaged and collapsed napkin PODs discovered after delivery to the customer’s warehouse
2) Strength the packaging structure by widening the support columns and adding support boards to each layer
3) Container loading method redesigned to eliminate gaps and reduce tilt risk during transit
4) On-site engineer deployed to supervise container loading and validate the updated method
5) Introduced a sideboard packaging method to further reduce the risk of POD collapse
They helped to improve the packaging security during shipping our products to the U.S., very good at finding the root cause and making changes to make sure the goods are protected.
A U.S.-based importer had worked with SVI for about five years on products supplied to major retail channels.
In September 2025, the first Holiday shipment of napkins arrived at the client’s warehouse with a serious packaging failure – damaged and collapsed napkin PODs.
The damage was linked to how the PODs were supported and loaded inside the container.
The pallets were stacked seven layers high, but the approved support boards only covered four layers. Empty space between the PODs inside the container also allowed the units to shift and tilt during transportation.
This reduced the overall support strength of the stack and increased the risk of the PODs collapsing before reaching the warehouse.
Products
Napkins
Channel
Major retail chains
Key risk
POD damage and collapse during transportation
What Was At Risk
This damage happened during the transition was due to the structural packaging issues:
- Multiple PODs arrived collapsed at the client's warehouse, creating stock and compliance issues
- The packaging structure was not providing enough support
- Empty space inside the container increased movement
- Repeated packaging failures risked chargebacks, returns, and damage to the retailer relationship
These gaps created significant exposure to timeline delays, quality inconsistency, and compliance failure risks.
What SVI Global Take to Solve the Challenges
We worked with the factory and customer to strengthen the overall shipping configuration and reduce the conditions that had caused the PODs to collapse.
1. Root cause analysis
Reviewed the full packaging structure and container loading configuration. Identified two compounding failure points: insufficient support column width and the absence of inter-layer boards beyond the fourth pallet level, combined with container gaps that allowed PODs to shift and tilt during transit.
2. Structural packaging redesign
Widened the four POD support columns from 70mm to 80mm
Added support boards to every layer of the pallet — not just the lower four
Upgraded strapping strength and increased the thickness of protective wrap around each POD
3. Container loading redesign
Changed the loading configuration and added air-filled bags throughout the container to eliminate gaps between PODs — directly addressing the tilt and collapse risk during sea transit.
4. Sideboard packaging adoption
Worked with the client to gain approval for a sideboard packaging method — a more robust structural approach that reduces collapse risk across all future shipments, not just the immediate fix.
5. On-site engineer deployment
Arranged for an engineer to be present on-site during container loading to provide direct supervision and ensure the updated method was executed correctly before the shipment was sealed and dispatched.
6. Retest & validation
Conducted retesting of the updated packaging structure to confirm it was structurally sound under load before approving it for production use.
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Final Outcome - What We Achieve
The packaging and loading improvements reduced the defect rate and improved the reliability of the napkin PODs during transportation.
- Structural and loading failures identified and corrected at source
- Column width, layer boards, strapping, and protective wrap all upgraded
- Gap elimination and air-filled bag deployment validated on-site
- The improved packaging and loading approach for subsequent shipments
Category:
Services:
Quality Control, Packaging Engineering, Production Management, Logistics
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