5 Common Causes of Cargo Damage in 2026 (And How to Prevent Them)

In international shipping, cargo damage is far more common than most first-time shippers expect.
Across ocean freight, minor to severe damage occurs regularly—especially on long-haul routes and consolidated shipments.

For traditional importers, a dented carton may be inconvenient but manageable.
For Amazon FBA sellers and B2B distributors in 2026, damaged packaging often means unsellable inventory.

If a shipment arrives at an Amazon fulfillment center with crushed corners, moisture stains, or compromised cartons, Amazon will classify the units as Unfulfillable. Sellers then absorb the product cost, shipping cost, removal fees, and lost sales—without recourse.

Many sellers attribute damage to “bad luck” or rough seas. In reality, most cargo damage cases can be traced back to packaging, palletization, or loading decisions made before the container doors are sealed.

Below are the five most common causes of cargo damage we see in 2026—and how experienced shippers prevent them.

1. Moisture & “Container Rain” (Cargo Sweat)

You load goods in a dry factory in Shenzhen.
Weeks later, when the container is opened in Los Angeles, cartons are damp, warped, or moldy—despite no visible leaks.

What’s happening

This phenomenon is known as Container Rain (or cargo sweat).

When containers move from hot, humid environments (southern China) into cooler ocean conditions, moisture inside the container condenses on the steel ceiling. Water droplets then drip directly onto cartons below.

This is especially common during summer shipments or long Pacific crossings.

Damp cardboard can lose up to half of its stacking strength, leading to collapsed cartons and product contamination.

How to prevent it

• Use high-absorption desiccants (calcium chloride poles or strips) hung inside the container

• Ensure container vents remain unobstructed unless product-specific rules require sealing

• Shrink-wrap pallets with top coverage, allowing moisture to shed away from cartons

2. Improper Palletization: The Overhang Problem

To maximize pallet density, some factories allow cartons to extend beyond the pallet edge—a practice known as pallet overhang.

Why this causes damage

The vertical stacking strength of a carton depends heavily on its corners.
When cartons hang beyond the pallet footprint, the load-bearing structure is compromised, and the bottom layer collapses under weight.

Amazon strictly prohibits pallet overhang. If detected, entire shipments may be rejected upon arrival.

How to prevent it

• No overhang: Cartons must remain within the standard 40" × 48" pallet footprint

• Use edge protectors (V-boards) to reinforce vertical stacking strength

• Standardize carton dimensions so pallets stack evenly without pressure points

👉 Related reading: Amazon FBA Packaging Requirements 2026

3. Poor Container Stowage (Shifting Cargo)

Even well-packed pallets can be damaged if they are not properly secured inside the container—a step that is often rushed or outsourced during loading.

During ocean transit, vessels may roll significantly. Any empty space between pallets allows cargo to shift, collide, or collapse. This is commonly referred to as shifting cargo.

How to prevent it

• Use dunnage bags to fill voids between pallets and prevent movement

• Balance weight distribution—never place heavy pallets on top of lighter ones

• Secure the final row near container doors to prevent forward collapse during braking

Poor stowage is one of the most overlooked damage risks because it happens after packaging—but before shipping responsibility is clearly defined.

4. Low-Quality Carton Materials

As raw material costs rise, some factories quietly downgrade carton quality unless packaging specifications are clearly defined.

A box may feel solid when dry and empty, but under prolonged stacking pressure, vibration, and humidity, low-grade corrugate buckles.

How to prevent it

• Always specify double-wall cartons for export shipments

• Avoid vague language like “strong boxes”

• Define measurable standards, such as Edge Crush Test (ECT) ratings (e.g., minimum 32 ECT)

Packaging quality issues are easiest—and cheapest—to catch before shipment leaves the factory.

👉 Learn more: Pre-Shipment Cargo Inspection Services

5. Rough Handling at Ports (The Human Factor)

Forklift punctures, dropped pallets, and crushed corners are unavoidable realities at busy ports.

Port operators handle thousands of containers daily under tight schedules. Even properly packed cargo can be damaged during loading, unloading, or yard movement.

What you can (and can’t) control

You cannot control port labor practices.
What you can control is your financial exposure.

How to protect yourself

• Apply Shockwatch or Tilt indicators to pallets to document impact events

• Understand carrier liability limits—often as low as ~$2/kg

• Use cargo insurance to protect full shipment value

At this stage, responsibility often shifts away from the factory and becomes a question of carrier liability versus cargo insurance coverage.

👉 Related guide: Freight Insurance: What’s Covered & What’s Not

Summary: Prevention Beats Claims

Once damaged cargo reaches an Amazon warehouse, recovery options are limited.

• Repackaging costs are high in the U.S.

• Lost sales during stockouts compound losses

• Customer experience suffers, even if damage occurred upstream

In practice, the most effective risk reduction happens before the container is sealed—through correct packaging, palletization, and loading controls.

At Forest Leopard, we support shippers with Container Loading Supervision (CLS) to ensure moisture control, proper dunnage, and compliant palletization before containers leave the factory.

👉 Contact Forest Leopard for a Shipping Quote & Loading Check