At the Packaging Doctor, we know that sending high-value and delicate items can be stressful. Whether it's a medical device or a custom product, ensuring it arrives in perfect condition is essential — not just for your customers, but for your business too.

One of our recent clients reached out with a specific concern. He sells knee trolleys across the UK and Europe and ships them via courier and air freight. These trolleys are made from aluminum, which makes them sturdy, but also vulnerable to damage during transit. He was worried that the cost of returns due to damage would eventually outweigh his profits.

We understand his concerns and were happy to help. Here’s what we recommended:

Dear Doctor,

I sell knee trolleys in the UK and Europe and send them via courier and air freight. They are made out of aluminum, and I'm worried that the cost of returns due to damage will end up being more than my profit. I hope you can help.

Thanks, John

Hi John,

Of course we can help — protecting your products is what we do best. Let’s take a look at how you can safely pack and ship your knee trolleys without worrying about damage.

First, we recommend using single-wall custom boxes with dimensions of 560x510x110 mm. These boxes offer the right balance of strength and affordability, making them ideal for shipping delicate items like your trolleys.

To protect the edges and corners of the trolleys, we suggest using edge protectors. Simply place them on all the sharp edges and secure them with tape or cable ties. This prevents dents and scratches during transit.

The wheels and legs of the trolley are particularly sensitive. If they're left loose, they can move around and cause internal damage. To prevent this, we recommend using bubble bags. These provide a soft, cushioned layer that absorbs shocks and keeps the trolley stable during transport. Plus, they come with a peel-and-seal strip for extra security.

Finally, don’t forget about branding. Custom logo tape is a great way to add your company’s name or logo to the packaging. It not only looks professional but also increases brand visibility with every delivery.

We hope these suggestions help you keep your products safe and your profits intact. If you have any more questions, feel free to reach out.

Best wishes, The Packaging Doctor

Note: All the packaging problems our doctor receives are real queries from customers or non-customers. If you have a packaging problem that needs diagnosing, get in touch: Twitter @kitepackaging or email us directly.

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