Packaging engineering has developed a 6 steps general system:
1) Distribution environment
The distribution channels for a company are analysed. The analyses include evaluation of all relevant risks. Data for the analyses can be recorded either by own equipment or by using relevant scientific results. Such evaluations include also a statistical evaluation, because a big impact only happens very seldom, which means that it will maybe happen once every 10,000 times. The companies need to document the chosen method in the firm.
2) Product fragility
First a test laboratory is used for testing the un-packed product in order to assess a critical level of stress. The product has an in-build protection to last. Test procedures are described later under each type of risk.
If the product is strong enough to last during distribution the procedure stops.
3) Upgrade distribution
Is distribution environment more tuff than the product you can evaluate if the problem can be solved by other distribution systems or you can ask for more quality from your supplier of distribution services!
4) Reinforce the product
If better transport is not a possible way you must look into your product and study what part was damaged. Can the product be upgraded for low costs and/or fast it is often cheaper than packaging.
5) Design packaging system
Have you no other options you need packaging. Engineering science has developed tolls for packaging design. Some of these methods are described later under every risk elements.
6) Test the packaging system
You are not able to calculate all the different impact on the product. And in the end you still have to test your packaging system.
Use the references to the scientific part of this homepage.