Packaging goals (what “export-ready” means)
Export packaging must do four jobs at once: prevent crushing, block fat/oil movement, control moisture, and survive handling across multiple touchpoints.
Key takeaways
- Crush damage is usually outer-box and palletization failure, not a product problem.
- Oil migration rises with heat and time—use better fat barriers and reduce headspace.
- Small upgrades (tray fit, corner boards, carton strength) prevent most export claims.
On this page
1) Preventing crush: build a “rigid stack”
Crush happens when weight transfers onto the product instead of the carton structure. The solution is a rigid system from tray to master carton to pallet.
Tray & inner pack
- Rigid tray: choose a tray that doesn’t flex under light pressure and supports edges/corners.
- Minimal headspace: too much empty space lets pieces bounce and corners chip.
- Piece locking: use dividers or cavities for assortments so pieces cannot slide into each other.
- Top protection: add a thin rigid sheet or lid insert to prevent rubbing and “shingling.”
Master carton (outer box)
- Use a high-strength corrugated carton sized so inner packs don’t rattle.
- Corner protection: corner boards or reinforced corners reduce edge crush.
- Correct fill: avoid soft fillers that compress and transfer load to the product.
- Stacking rules: print “Do not stack” only when you can enforce it—otherwise build to survive stacking.
Palletization
- No overhang: cartons must align to pallet footprint (overhang is a top cause of damage).
- Interlock stacking: improves stability and reduces slippage.
- Corner boards + stretch wrap: boards take vertical pressure; wrap keeps the load stable.
- Top cap: a rigid top sheet distributes pressure from any additional handling.
2) Preventing oil migration: barrier + temperature strategy
Oil migration is usually a combination of heat exposure + time + insufficient fat barriers. When fats soften, they can move into papers/boards and create stains or “wet” appearance.
What works best
- Fat barrier inner wrap: use food-grade films/laminates designed for fat resistance.
- Keep product stable: avoid loading warm product; reduce exposure to hot terminals/warehouses.
- Absorbent pads (where appropriate): place only where they won’t touch the pastry surface or affect presentation.
- Tight fit: limiting movement reduces rubbing that spreads oil onto surfaces.
If you ship to hot climates or face long holds, pair packaging upgrades with route planning (see: Cold Chain or Ambient?).
3) Humidity & crunch: the silent quality killer
Baklava loses crunch mainly through moisture pickup and syrup redistribution. The goal is not “bone dry”—it’s stable moisture.
- Moisture barrier: seal inner packs well; weak seals invite humidity.
- Desiccants (when suitable): for long routes, humidity control can protect crispness—use only food-safe packs and correct sizing.
- Avoid condensation traps: sudden temperature changes can create moisture inside packaging; route stability matters.
Export packaging spec checklist
- Inner pack: sealed, fat/moisture resistant material, minimal headspace.
- Tray: rigid, supports edges, prevents piece movement.
- Outer carton: high-strength corrugate, tight fit, reinforced corners.
- Labeling: “Keep cool & dry”, orientation arrows, handling icons as needed.
- Pallet: no overhang, corner boards, stable wrap, top cap.
Quick QA tests before scaling
- Compression check: simulate stacking pressure; verify cartons carry load without bowing.
- Drop/impact check: corner and edge drops reveal weak points fast.
- Heat exposure check: short controlled heat exposure to see if oil staining appears on inner/outer materials.
- Shake test: confirms headspace and piece locking for assortments.
FAQ
What causes crushed baklava most often?
Over-stacking and weak cartons—especially when cartons overhang pallets or corners aren’t protected. Build the “rigid stack” so weight stays on the carton structure.
Is oil migration always a product defect?
Not necessarily. Many oil-stain issues are packaging + heat exposure problems. Improve fat barriers and reduce hot holds, and the issue often drops dramatically.
Related: Incoterms for Sweets • Export Documents Checklist