Damage Isn’t Inevitable, It’s Engineered
Many businesses treat shipping damage as an unavoidable part of operations.
Broken goods? Blame the carrier.
Crushed cartons? Order thicker boxes.
But after working across furniture, glassware, machinery, electronics and e-commerce for over two decades, Rebul has learned something else:
Most freight damage isn’t caused by the outside world, it starts inside the box. Which means prevention isn’t about more packaging, but smarter packaging.
That’s where engineered internal packaging support becomes a competitive advantage and why the right system can reduce breakage rates by up to 80%.
The Hidden Cost of Poor Internal Packaging
Damage costs more than replacement stock. There’s return freight, rework labour, credits, downtime, customer dissatisfaction and insurance friction.
Internal packaging usually accounts for less than 10% of total packaging cost, yet directly influences most damage outcomes.
If your internal supports don’t secure, stabilise and protect your product, you are paying for packaging… but not protection.
What Actually Causes Product Damage?
Understanding breakage starts with understanding risk.
Most damage comes from:
✔ movement during transport
✔ impact force at weak points
✔ uneven weight distribution
✔ vibration or rubbing
✔ stacking inefficiency
✔ insufficient internal restraint
Better boxes won’t solve that. Better internal support will.
Smart Internal Packaging Support, Where Damage Prevention Begins
Internal packaging support isn’t one product. It’s a system engineered around your product and shipping conditions.
Rebul specialises in designing that system, which is why our clients see measurable drops in breakage rates, cost and freight inefficiency.
Here’s how internal support works in practical terms.
Types of Internal Packaging Supports & Their Benefits
Rebul doesn’t supply packaging pieces, we engineer an internal support system around your product, handling conditions and risk profile.
Void Fillers — Stopping Movement Before It Starts
Movement is the single biggest cause of breakage during transport. Rebul’s engineered void fillers eliminate internal space so products cannot shift, collide or vibrate.
We design void solutions to:
✔ minimise freight returns
✔ protect delicate surfaces
✔ speed up packing processes
✔ reduce wasted materials
Edge & Corner Protectors, Reinforcing Critical Weak Points
Edges and corners are the first points to take impact – especially when items are stacked, strapped or mechanically handled.
Rebul edge & corner protectors are designed to:
✔ absorb shock
✔ prevent crush failure
✔ support vertical load bearing
✔ add confidence to pallet stacking
Industries that rely heavily on this include furniture, cabinetry, framed artwork, industrial components and electronics.
Support Inserts for Fragile Products
Rebul support inserts are engineered to:
✔ control tilt
✔ isolate sensitive surfaces
✔ prevent abrasion & vibration
✔ hold delicate items in a fixed position
We work with art shippers, premium retailers, manufacturers and glass suppliers to protect product integrity, not just freight movement.
Base Cushioning & Strengthening
Heavy goods fatigue cartons and pallet bases, especially over distance.
Rebul designs structural base systems that:
✔ improve stacking performance
✔ increase handling stability
✔ replace unnecessary pallet weight
✔ minimise damage when items are dropped or slid
This is particularly valuable for machinery, appliances, e-commerce bulk loads and bulky furniture, helping businesses reduce cost while increasing handling safety.
Carton Reinforcement Systems
Sometimes the box fails long before the product does.
Rebul reinforcement systems:
✔ increase directional strength
✔ prevent side wall collapse
✔ enable higher stacking in storage or transit
✔ extend the usable lifespan of cartons
This type of support is ideal for warehouses, distribution centres and export shipments where cartons are cycled multiple times.
Interlayer Sheets
Weight concentration is a silent destroyer of packaging.
Rebul interlayer systems:
✔ spread load pressure evenly
✔ reduce crushing between stacked items
✔ stabilise multiple SKU shipments
✔ help retain box integrity through long freight routes
This is why interlayers are highly valued in e-commerce, retail logistics and manufacturing supply chains, where dozens of products travel together.
Custom Internal Frames & Inserts
Most products don’t fit “standard” packaging well and friction inside cartons costs businesses money.
Rebul engineers internal frames that:
✔ match your product geometry
✔ secure items in fixed spatial positions
✔ improve carton orientation control
✔ reduce touchpoints where damage occurs
This level of customisation is only achievable because Rebul isn’t a commodity supplier — we’re a design-and-manufacture partner.
Material Flexibility. Because One Material Doesn’t Solve Every Problem
Unlike suppliers who push one material category, Rebul is solution-first, not material-first.
We design systems using:
• honeycomb board
• corrugated substrates
• structural laminates
• cushioning elements
• timber & engineered components where required
This ensures your business gets:
✔ the right strength
✔ the right weight
✔ the right compliance outcome
✔ the right handling experience
Not one material for every situation.
Internal Packaging Is a Performance System, Not a Catalogue
Buying void fillers from one source, edge protectors elsewhere and reinforcement panels online doesn’t guarantee protection. Protection happens when these components are designed to work together Rebul’s strength is that we don’t just supply packaging, we engineer stability environments.
This includes:
✔ sizing
✔ orientation
✔ compression mapping
✔ contact surface design
✔ shipping risk assessment
How Internal Packaging Support Cuts Damage by Up to 80%
When loads stop shifting, when edges don’t absorb direct force, when weight distributes evenly inside the carton…
Damage doesn’t just reduce, it is largely prevented.
That’s why companies across manufacturing, retail, freight logistics, e-commerce, furniture and art rely on Rebul.
How to Get Started With Rebul
Step 1 – Submit Your Requirements
Tell us what you ship, where it goes and any frustrations you’re facing.
Step 2 – Receive Your Engineered Solution
We design internal supports specific to your product.
Step 3 – Approve and Manufacture
Made locally — delivered anywhere in Australia.
Step 4 – Ship with Confidence
Experience fewer damages, less waste and better handling.
Logistics shouldn’t be stressful. Packaging should solve problems, not create them.
From fragile goods to heavy industrial loads, Rebul designs the internal support systems that keep your products safe and your customers happy.
