Packaging protects products throughout the supply chain. Structural failures, incorrect printing, and material inconsistencies lead to product damage, brand embarrassment, and retailer chargebacks. The cost of a packaging defect is multiplied by the value of the product inside.
Packaging typically uses AQL 1.5 to 4.0. Critical structural defects (burst strength, compression) warrant AQL 1.0, while print variations and minor cosmetic issues may use AQL 4.0.
| Defect Type | AQL | Inspection Level | Notes |
|---|---|---|---|
| Critical (structural failure) | 1.0 | General II | Burst/compression testing |
| Major (print error, dimension) | 2.5 | General II | Colour Delta E < 3 |
| Minor (surface marks, slight variation) | 4.0 | General I | Industry standard tolerance |
Corrugated cartons failed BCT (Box Compression Test) during AQL 1.0 inspection. The supplier had changed paper grade without notice. Rejection prevented collapse of palletised goods during ocean freight.
AQL 2.5 inspection with spectrophotometer confirmed all folding cartons met the brand Delta E < 2 requirement across a 500,000-unit print run.
Skipped inspection allowed warped corrugated trays to ship. The retailer rejected the entire pallet, charged back $45,000, and placed the supplier on probation.
