A notable share of complaints stems not from manufacturing errors but from packaging: dents on parts knocking against each other, rust on uncoated steel, chips in a hydraulic part that should have been clean. Packaging is the first link in the logistics chain and accounts for 1–3% of the part price; cutting this cost usually ends up far more expensive.
The Four Objectives of Packaging
- Corrosion protection: Uncoated steel and cast iron rust over 3,000 km by road through temperature and humidity cycles.
- Preventing mechanical damage: Edge dents, scratches, thread damage, bending of thin parts.
- Preventing contamination: Chips, dust, packaging fibres; critical for hydraulic, medical and optical parts.
- Identification and traceability: Right part, right quantity, right batch; saves time at incoming inspection.
Corrosion Protection
- VCI (volatile corrosion inhibitor) paper or film: Creates a protective atmosphere inside closed packaging; 6–24 months of protection. The standard solution for steel, cast iron and most alloys; leaves no oil residue and requires no washing at incoming inspection. The packaging must be sealed airtight and the distance between part and VCI must not exceed 30 cm.
- Protective oil / dewatering fluid: A thin film on the part washed after machining; used together with VCI for long storage and sea freight. If the customer needs oil-free parts (assembly line, bonding), this must be stated in the RFQ.
- Desiccant (silica gel) and aluminium barrier foil: For sea freight and tropical climates; combined with VCI.
- Stainless steel, aluminium, brass: VCI is generally unnecessary; however, contact between dissimilar metals (galvanic corrosion) is avoided; for aluminium, a dry environment is sufficient against white rust.
- Coated parts: Coatings such as zinc and nickel withstand transport corrosion; the real risk is mechanical damage.
Preventing Mechanical Damage
- Part-to-part contact must be eliminated: Toleranced parts with surface requirements are not shipped in bulk. Solutions: foam or plastic cavity trays (blisters), cardboard grid dividers, individual bags, tube or channel packaging (for long thin parts), bubble film.
- Bulk packaging only for: Parts with tolerances ≥ ±0.1 mm, no surface requirement, coated or simple parts; box weight must not exceed 10–15 kg.
- Threads and sharp edges: Plastic protective caps or individual wrapping; threaded parts do not touch each other.
- Long and thin parts: Shafts and bars are shipped horizontally and supported; no voids are left inside the box (foam filler, air cushions).
- Heavy parts: Parts above 15 kg individually or secured on a pallet; manual handling limits per person (typically 15–25 kg in the EU) are observed.
Box, KLT and Pallet Standards
| Packaging | Standard / size | Use |
|---|---|---|
| Cardboard box (single/double wall) | 400×300, 600×400 mm footprint matching the pallet module | One-way export packaging; double wall up to 15 kg |
| KLT plastic container | VDA 4500: 300×200, 400×300, 600×400 mm; height 147/213/280 mm | Automotive returnable packaging; supplied by the customer or purchased |
| Euro pallet | EPAL 800×1200 mm, 1,500 kg dynamic load | Road transport standard; full use of truck width |
| Industrial pallet | 1000×1200 mm | For some warehouses; must be agreed in advance |
| One-way wooden pallet | ISPM 15 heat-treatment stamp | Mandatory for all wooden packaging entering the EU from a third country (including Turkey) |
| Plastic or pressed-wood pallet | Outside the scope of ISPM 15 | Preferable for air freight and to avoid fumigation issues |
Pallet rules: height including pallet 1.2–1.8 m (depending on the customer's warehouse), boxes do not overhang, flat top (stackable), corner protectors + strapping + stretch film, heavy boxes at the bottom, total weight and markings such as "do not stack" on top of the pallet. Wooden pallets shipped from Turkey to the EU must carry the ISPM 15 stamp; an unstamped pallet risks being held or destroyed at customs.
Labelling and Documents
- Box label: Customer part number, supplier part number, description, quantity, batch/lot number, production date, supplier name, revision where required. In automotive, the VDA 4902 or Odette/GTL label format (with barcode) is standard; the customer template should be shared in the RFQ.
- Pallet label: Total quantity, number of boxes, gross/net weight, order number, delivery address; "MIXED" marking on mixed pallets.
- Documents: Delivery note/packing list in a document pouch on the outside of the pallet; inspection report and 3.1 certificate inside the box or sent electronically in advance. Customs documents (invoice, A.TR/EUR.1) with the carrier.
- No mixed batches: One part number and one batch per box; mandatory for traceability.
Technical Cleanliness
In parts for hydraulic, pneumatic, fuel and brake systems, residual chips and particles mean failure at assembly. If there is a VDA 19 / ISO 16232 technical cleanliness requirement (e.g. "particle size ≤ 400 µm, residue weight ≤ 2 mg/part"), it must be on the drawing; the supplier applies washing, drying and clean packaging (sealed bag, dust-free tray). Clean parts are packed separately so they cannot be recontaminated, and the packaging is closed in a clean area. Cleanliness and traceability requirements are described in our automotive suppliers article.
Returnable Packaging
For regular shipments, customer-owned KLT containers and special trays go out full and come back empty. On the Turkey–Europe lane, because of the empty return cost and a 2-week cycle, a packaging stock of typically 3 cycles is needed. Alternative: the supplier uses one-way cardboard plus cavity cardboard dividers and the cost is added to the price. The decision is made based on quantity and part value.
Packaging Specification for the Supplier (Template)
- Part number and revision.
- Corrosion protection: VCI / oil / oil-free; target protection period.
- Unit packaging: individual bag / cavity tray / bulk; quantity per box.
- Box type and size; maximum box weight.
- Pallet type, maximum height, ISPM 15, stacking rule.
- Label format (template attached) and barcode content.
- Cleanliness requirement (VDA 19 class) and packaging environment.
- Documents: where, in which format.
- Returnable or one-way; owner of returnable packaging and number of cycles.
- Pre-shipment photo request (open box, closed pallet).
This specification should be part of the RFQ package; packaging requirements added later lead to price changes.
Frequently Asked Questions
Is VCI sufficient, or is oil also needed?
For road transport and 1–3 months of storage, sealed VCI packaging is sufficient; for sea freight, storage over 6 months or machined cast iron, VCI plus a thin oil film is recommended.
Is ISPM 15 really mandatory for wooden pallets?
Yes; as Turkey counts as a non-EU country, all wooden packaging entering the EU (pallets, crates, blocks) must carry the ISPM 15 stamp. Plastic pallets are outside this rule.
Who bears the packaging cost?
Standard export packaging is included in the quoted price; special trays, KLT or clean-room packaging are stated as a separate line.
Is it normal to request pre-shipment photos?
Yes, and it is recommended; photos of the open box and closed pallet clarify responsibility in case of damage.
Conclusion
Correct packaging means corrosion protection with VCI, dividers eliminating part-to-part contact, ISPM 15-stamped EPAL pallets, standard labels and, where required, technical cleanliness discipline, and its cost is a small percentage of the part value. Tornelle applies these rules as standard in its shipments and works to customer packaging specifications. If you would like to define the appropriate packaging solution for your part at the quotation stage, send your technical drawings and packaging expectations via our quote form.
