How UK manufacturers should pack automotive parts for transport

The automotive industry is often defined by its scale, yet that scale is easy to overlook in day-to-day operations. As the sector continues to evolve through electrification and global supply chain change, its economic and industrial influence remains significant worldwide.

According to the Society of Motor Manufacturers and Traders (SMMT), the UK automotive industry generates around £92 billion in turnover and contributes approximately £25 billion in Gross Value Added (GVA) to the UK economy. The sector also supports around 796,000 jobs across manufacturing, retail and the wider automotive supply chain.

In 2025, UK manufacturers produced 764,715 vehicles, including 717,371 cars and 47,344 commercial vehicles, alongside approximately 1.6 million engines. The SMMT also reports that nearly eight in ten UK-built cars are exported, reaching more than 140 international markets worldwide. Car parts packaging takes many forms, from returnable containers used within the supply chain to corrugated boxes for aftermarket parts. It can be designed to improve handling, protect components in transit and increase production line efficiency.

If you work in the automotive industry, this guide to car parts packaging will give you a clear overview of key considerations and practical options available to you. Whether you're at an OEM or a tier 1, tier 2 or tier 3 supplier, it highlights proven solutions for packing and shipping car parts efficiently and reliably.

Considerations when packing and shipping automotive parts

Before looking at the varying types of car parts packaging, it is essential to consider several factors. The six primary considerations for car parts packaging are:

1. The weight of the product/part you are shipping
2. The fragility of the parts
3. How valuable are the items you are shipping
4. The packing and unpacking processes
5. How your parts (and packaging) are handled in the supply chain
6. Any impact on the environment

Weight of products

The weight of your parts or components is important when specifying your automotive packaging. Heavier items need more durable packaging to ensure it does not fail during transit. Lighter items should have their packaging optimised to minimise weight and reduce costs and CO2 emissions through the supply chain.

Fragility of parts

How delicate your car parts are also influences the best packaging for your business. You may require cushioning and inserts to minimise damage caused by handling in the supply chain, although even the more robust items still need protection. You should also consider protection for surface finishes on painted, polished or decorative surfaces.

How valuable are the items you are shipping

The packaging used for high-value items, such as infotainment units or gearboxes, requires a different specification from that used for lower-value components, like plastic trims or ancillary parts.

Packing and unpacking processes

It is crucial to consider how quick and easy it is to pack and unpack your products. Does your car part packaging use much secondary packaging such as bags, inserts or films? Is it easy to pack multiple smaller parts in the same outer container? Are there any additional processes that packing teams need to carry out which may impact production times and efficiency?

How do transport providers handle parts during transit?

Consider how your items are handled within the supply chains. Are there many touchpoints that could result in mishandling? Does packaging need to look presentable at its destination (e.g. for aftermarket parts or retail items)?

It is also essential to account for the methods of transport and the environments your car parts packaging may encounter – for example, whether it will be left outside or exposed to moisture.

Impact on the environment

The final consideration is the impact that your packaging has on the environment. Does it allow you to maximise transport efficiency, or are you shipping lots of empty space? Can any single-trip packaging be easily recycled by the end user? Would returnable or extendable packaging be most suitable?

Expendable vs returnable

This final point leads nicely to arguably the most important consideration for shipping car parts – whether to use expendable or returnable packaging. But how do you decide which is best for your business?

Generally, the longer the distances involved in the logistics leg, the less practical it becomes to use returnable packaging. Most of the returnable automotive packaging is used within short loops and those with fixed arrival and distribution points.

Of course, you may not have reliable return transport, your parts are for use by the end consumer (hence the packaging cannot be returned) or it is not economical to return empty containers to your warehouse or manufacturing site.

Another point to consider at the outset is what different manufacturing plants or customers accept. Many do not have facilities to dispose of large volumes of single-trip packaging and only accept products in returnable packaging. Others may specify expendable packaging. It is vital to check what your customers want!

Returnable supply chain packaging

However, it is likely that, as part of an automotive supply chain, you will use returnable packaging of some description.

Due to the vast numbers of parts and overall throughput of vehicle manufacture, using returnable containers eliminates the generation of huge amounts of packaging waste compared with single trip. Returnable containers are typically more robust, offering better protection for parts, and are often designed to industry standard sizes that improve space efficiency in transport and production lines. They also enable safer stacking and handling.

And arguably the most crucial point, returnable packaging provides a lower cost per trip or lifetime cost than expendable packaging.

Euro containers

Euro containers are the most used returnable packaging for car parts and components. Often referred to as KLT containers or ALC (Attached Lid Containers – when including a lid), these moulded plastic boxes are available in standard sizes to be compatible with most pallets, racking, conveyors and so on. They are both cost-effective and robust, hence their popularity and widespread use.

Correx tote boxes

The main limitation of Euro containers, however, is their standard sizing. Fixed dimensions can sometimes mean wasted space within containers when shipping unusually shaped or sized items. This issue reduces transit efficiency and can also mean adding a large volume of void fillers or other inserts. It also reduces assembly line part density.

As a result, a returnable packaging option that is growing fast in popularity is Correx tote boxes. The key benefit is that you can opt to manufacture them in custom sizes. This size flexibility means they can accommodate unusually shaped items or a defined number of parts for a specific assembly.

Correx totes are also lighter than moulded containers, which can help reduce transit costs and emissions. And, due to a range of material options, you can select to have them manufactured with strength comparable to euro containers or tailored to the requirements of specific items.

Expendable packaging

Despite the benefits of returnable car part packaging, there are scenarios where single trip or expendable packaging would be most suitable. As well as parts that ship directly to end users, there are uses within supply chains for these options. Particularly where parts travel long distances and/or return is difficult.

Heavy duty corrugated

Many businesses use corrugated packaging within automotive supply chains. Like Correx, it offers the advantage of being easily manufactured into custom-sized boxes. Bespoke sizing helps improve space efficiency and can reduce transport costs and emissions. A range of heavy-duty grades is available, including double- and triple-wall options that offer impressive durability.

Other benefits include the ability to print handling instructions directly onto the packaging, as well as the ease with which cardboard can be recycled.

Timber crates and cases

Timber crates are another option in certain parts of automotive supply chains. Like corrugated, they can be easily produced in bespoke sizes to accommodate specific parts. They are particularly suited to shipping larger panels, assemblies or even engine blocks. Whilst they can offer some reusability, they are also more challenging to dispose of and more costly than cardboard equivalents.

Dunnage and inserts

Whether you use returnable or single-trip packaging to ship your car parts, you can enhance the performance and efficiency using dunnage – effectively different forms of inserts.

Inserts improve part density within an outer container, helping to maximise space efficiency while making packing and unpacking quicker and easier. They also reduce the risk of damage by limiting movement and preventing components from colliding during transit. In addition, inserts can provide precise positioning of parts, supporting efficient and accurate robotic assembly.

Divisions

Simple divider sets manufactured using Correx or even cardboard can provide all the benefits mentioned earlier. Usually created to suit a specific product or assembly process, you can choose the cell size and configuration (e.g. 4 x 4 cells within the container). Dividers can be removable and folded flat or integral to the construction of Correx totes or trays.

Textile dividers

Some parts – for example, interior fittings or painted parts – have decorative surfaces that customers can reject due to surface scuffs or marring. If this is a concern, using a material such as Bubble-board can eliminate this. The plastic material is laminated with spun-bond fabric to protect from scratches or foam to provide additional cushioning during shipment.

Custom inserts

For unusually shaped parts, custom fittings can provide a perfect fit for the item in question.

Vacuum-formed trays

Vacuum-formed trays are another option widely used to handle car parts and components. They have recesses moulded to the exact shape of the items they carry to provide protection and ease of packing/unpacking.

Foam

Finally, you can use various foam inserts for particularly delicate or high-value items. As per vacuum-formed trays, foam inserts can precisely match the contours of any part or component. They go a step further, however, in that they also provide excellent cushioning protection.

Specialist software allows for the optimum level of protection to be engineered into the foam packaging – crucial for high-end parts that cost thousands of pounds.

Airsac cushioning protection

Airsac is an inflatable packaging solution that moulds to your products and can be used for both small automotive components and larger body panels, such as doors and bonnets. It utilises pockets of air to provide high levels of protection, making it extremely light and easy to handle. Available in a range of formats, such as a full bag or end cap, it can be used to replace traditional cushioning products, like foam or stratocell.

As it’s inflated on demand, Airsac is an excellent way to remove bulky packaging from the packing process and free up storage space on site.

Protecting car electronics

As technology advances, an increasing number of vehicle systems depend on electronics and microchips. From telematics and navigation to driver assistance systems and infotainment units, modern vehicles are built on increasingly sophisticated technologies. However, these parts and components can be susceptible to a different form of damage – electrostatic discharge (ESD).

What is ESD?

ESD is the transfer of an electrical charge between two objects. Whilst this occurs naturally, the heat generated during this process can cause significant damage to microchips and electronics. And whilst the effects may not be immediately apparent, latent damage can result in performance degradation and decreased lifespan of items that rely on electronics to function.

Conductive packaging options

Due to this, several anti-static and conductive packaging products are commonplace in automotive industries.

Corstat – a corrugated cardboard with a carbon coating – creates a “faraday cage” effect. This essentially channels any static around the outside of the packaging, protecting any items within. Plastic options, including Corriplast conductive Correx and moulded plastics, operate similarly, whilst various ESD-safe foams are also available.

Other specialist car parts packaging

Several other specialist packaging applications are common within the automotive manufacturing industry.

VCI protection

A volatile corrosion inhibitor (VCI) is a material that protects metals from corrosion (i.e. rust). Vehicles use a considerable amount of metal components, so shipping these over long distances has the potential for this type of damage to occur.

Numerous VCI papers and bags are available to pack components in, whilst others may be coated in grease or similar substances to protect them during shipping. However, all these add another process to packing and unpacking operations. An alternative is to coat your packaging with a VCI material, which can provide an equivalent level of protection.

Scuff protection

As mentioned earlier, inserts and dividers can be manufactured using material that prevents surface scuffing and marring. These properties are essential for painted, polished or coated parts or those which form part of the interior of a vehicle. What is less well known is that cardboard can be surprisingly abrasive, although again, there are coatings for corrugated boxes that can help to minimise this.

Lithium batteries

A new challenge facing automotive manufacturers and parts suppliers is lithium batteries. Prevalent in electric vehicles, the UN classifies li-on batteries as hazardous goods. This classification requires specialist packaging that meets defined regulations (UN3480) to ship.

Options for this include returnable aluminium cases with specialist inserts that contain fires should batteries fail or malfunction during transportation.

Spares, eCommerce and retail

Of course, not all businesses in the automotive sector supply parts used directly in the manufacture of new vehicles. Many provide spares and aftermarket parts that go straight to service centres, garages and even consumers.

The UK automotive aftermarket generates around £21 billion in annual turnover, according to the SMMT. Packaging for shipping car parts faces different challenges. It is typically designed for single use, as there is often no practical option for return. As a result, recyclability must be balanced with performance, ensuring the packaging can withstand the demands of courier and postal networks and the multiple handling points involved.

The packaging required for shipping these car parts faces different challenges. Firstly, it tends to be a single trip as there is no easy option for returning it. Being expendable means considerations surrounding recyclability must be balanced against ensuring it performs well within courier and postal networks and the multiple touchpoints these comprise.

In some instances, there may even be a requirement to add branding, instructions and other information, as some parts may be displayed within retail stores or be required to provide some form of limited “unboxing” experience.

As such, businesses typically use corrugated packaging for applications of this type.

Looking for the right packaging solution?

Whether you work for an OEM or a tier 1, 2 or 3 supplier, the packaging experts at GWP and Macfarlane Packaging can help you identify the most suitable solution for your specific application.

Speak to the team for tailored advice and guidance on selecting the right packaging for your business.is on hand to ensure you select the most suitable car parts packaging for your specific application.

Get in touch today for advice and guidance on sourcing the optimum packaging for your business.