How to Prevent Fruit and Vegetable Damage from Crushing in Plastic Boxes？
Fruits and vegetables are highly perishable, and crushing during transportation or storage is a major cause of product loss in the industry. Using plastic boxes is a common solution, but proper strategies are needed to maximize protection. Here are practical ways to avoid crushing damage:
1. Choose the Right Plastic Material
Not all plastics are equal for produce protection. Opt for high-density polyethylene (HDPE) or polypropylene (PP) boxes. These materials balance rigidity and flexibility—they resist cracking under pressure while absorbing minor impacts. Avoid thin, low-grade plastics that deform easily; look for boxes with a thickness of at least 2-3mm. For delicate items like berries or leafy greens, select food-grade plastics with smooth inner surfaces to prevent scratches that weaken produce and lead to bruising.
2. Prioritize Structural Design Features
The box’s design plays a key role in distributing weight evenly. Look for boxes with:
● Reinforced edges and corners: These areas bear the most pressure when stacks are formed. Reinforcements prevent the box from collapsing inward.
● Perforated sides and bottoms: While ventilation primarily controls moisture (which also reduces rot), it also lightens the box’s overall weight. Lighter boxes put less pressure on the produce below when stacked.
● Stacking ribs or anti-slip bases: These features keep boxes stable when stacked, avoiding shifting that causes uneven pressure. Unstable stacks often lead to boxes tilting and crushing lower layers.
3. Control Stack Height and Weight
Overstacking is the top cause of crushing. Even durable boxes have weight limits—never exceed the manufacturer’s recommended stack load (usually marked on the box). For heavy produce like apples or potatoes, limit stacks to 4-5 boxes; for lighter items like lettuce, 6-7 boxes may be safe, but test first. Place heavier boxes at the bottom and lighter ones on top to reduce downward pressure. If using pallets, use pallet jacks or forklifts carefully to avoid sudden jolts that compress the stack.
4. Use Dividers and Liners
For small or fragile produce (e.g., cherry tomatoes, peaches), add plastic dividers or corrugated cardboard inserts inside the box. Dividers create individual compartments, preventing items from shifting and bumping into each other during movement. For extra protection, line boxes with soft, food-safe liners like non-woven fabric or bubble wrap—these cushion impacts and reduce direct pressure on the produce.
5. Optimize Loading and Unloading
Handle boxes gently to avoid sudden drops or impacts. Train staff to load produce in a single layer when possible; if layering is necessary, place a thin sheet of cardboard between layers to distribute weight. Avoid piling produce too tightly—leave a small gap (1-2cm) at the top of the box to prevent compression when the lid is closed. During unloading, never throw or drop boxes, as even short falls can cause internal crushing.
6. Regularly Inspect and Maintain Boxes
Worn or damaged boxes lose their protective ability. Check boxes for cracks, bent edges, or weakened bottoms before each use. Replace any boxes that show signs of damage—using faulty boxes increases the risk of collapse. Clean boxes regularly with mild, food-safe cleaners to remove dirt or residue that can cause friction and damage produce.
By combining the right plastic box selection, smart design use, and careful handling, businesses can significantly reduce crushing damage. This not only cuts down on waste but also preserves the quality of fruits and vegetables, ensuring they reach consumers in fresh condition.
