ESD Packaging: How to Package Static-Sensitive Electronic Components for Shipping

If your business manufactures or assembles static-sensitive electronic devices or components, ESD packaging should be a core part of your operational strategy.

In this article we will cover:

• What is ESD packaging
• The risks of shipping static-sensitive electronics
• ESD packaging options
• How to safely pack static-sensitive electronic components for shipping
• Considerations when selecting the right ESD packaging

What Is ESD Packaging?

ESD packaging protects electronic parts, components, and finished products from harmful electrostatic discharges. It prevents damage to static-sensitive items like printed circuit boards, semiconductors, microchips, and electronic devices that incorporate these components. In addition to shielding against static, ESD packaging also offers physical protection, making it ideal for storage, transportation, and handling throughout the supply chain.

The Risks of Shipping Static-Sensitive Electronics

Electronics are vulnerable to a range of hazards during transit, many of which can cause serious damage without proper protection.

Key risks include:

• Extreme temperatures: Excessive heat or cold can compromise internal components, particularly batteries.
• Moisture exposure: Humidity or accidental contact with water can lead to corrosion or electrical shorts.
• Electrostatic discharge (ESD): Static electricity can irreparably harm static-sensitive parts such as microchips and circuit boards.
• Physical impact: Shocks from drops, bumps, or vibrations may crack or dislodge internal elements.

Understanding these risks is the foundation for choosing the right protective measures and ensuring your products arrive safely and intact.

ESD Packaging Options

There are many different types of ESD packaging options to choose from. Listed below are some of the most commonly used packaging options that you should consider when it comes to shipping your electronic component or device.

ESD Bags

ESD bags offer a cost-effective solution for safeguarding static-sensitive electronic components and devices. However, their durability can be compromised by sharp edges or pointed corners, which may puncture the material and reduce their protective effectiveness.

ESD Foams

A variety of specialist static protective foams can be incorporated into ESD packaging to enhance protection. These foams not only cushion contents for superior physical safety but also offer reliable static control. Available options include pink anti-static foam, static dissipative and conductive types.

The high-density conductive foam can provide protection for pins on static-sensitive electronic components when places inside bags, trays, and compartments.

Conductive Euro Containers & Component Boxes

Conductive euro containers and conductive component boxes provide a durable and ESD-safe packaging solution for static-sensitive electronic components. Made from a polypropylene material, the ESD boxes offer increased lifespan and easy to clean surfaces which enhance longevity.

The high-strength material delivers exceptional physical protection – protecting items against drops, crushing, and routine handling throughout transit and storage. They can reduce your costs by minimising damaged caused by static or mishandling.

Corstat

Corstat material features a conductive carbon black coating that, combined with its structural design, creates a Faraday cage effect. This effectively shields enclosed items from electrostatic discharge. Beyond its protective properties, Corstat offers additional advantages, such as: easy to recycle, safe to handle, and available in both standard and custom packaging sizes to suit a wide range of applications.

Correx / Corriplast

Correx is a conductive corrugated plastic that performs similarly to Corstat but adds additional strength and resistance to moisture and chemicals. It is a durable, static safe material that does not shed fibres – this makes it suitable for use in cleanroom environments when static protection is also required. In addition, it is also suitable for use over multiple trips.

How to Safely Pack Static-Sensitive Electronic Components for Shipping

Secure Internal Items to Prevent Shifting

Even with robust outer packaging and ESD protection, internal movement of contents remains a significant risk during transit. Vibrations and impacts can cause items to shift, collide, or grind against each other, especially when excess space is left inside the box.

To minimise this risk, consider the following:

• Choose the correct box size. Ensure no more than two inches of space between the product and the box walls.
• Fill all voids with protective materials such as ESD foam corners, conductive cardboard inserts, vacuum formed packaging, or conductive component trays tailored to your product’s dimensions.
• Wrap each item securely. Pay special attention to edges and corners, which are most vulnerable to shock.
• Use dividers or custom inserts when shipping multiple components to create individual compartments and prevent contact between items.
• Secure loose parts separately. Cables, caps, and connectors should be packed in ESD bags or dedicated compartments, with cushioning above and below to prevent movement.
• Apply pressure-sensitive tape to hold wrapped items in place if necessary.

Proper internal packaging not only protects your products – it reinforces your commitment to quality and reliability.

Use Shock and Vibration Absorption

Static-sensitive electronic components and devices are highly susceptible to shock and vibration, which can damage internal components and impair functionality. To mitigate these risks during transit, consider using custom cases engineered with shock-absorbing features such as foam inserts, conductive layer pads, or divider sets.

Optimise Packing Techniques

Improper packing can put electronics at risk to damage. Therefore, it is essential to follow best practices for packing:

• Individually wrap each component using anti-static bubble wrap or foam sheets to guard against electrostatic discharge and surface damage.
• Use custom-cut foam inserts to secure components in place, ensuring a snug fit.
• Fill all empty spaces within the container to prevent shifting and absorb impact during transit.

Strategic packing not only reduces contact between items but also minimises the chances of scratches, pressure-related damage, and internal misalignment. This preserves both the appearance and functionality of your electronics.

Use Humidity and Temperature Controls

Static-sensitive electronic components are vulnerable to extreme temperature and high humidity, which can lead to degradation or failure. For shipments that require climate control, it’s essential to use packaging solutions that regulate temperature and moisture.

• Use moisture barrier bags to protect electronic components and devices from moisture and static damage during storage and transportation.
• Add desiccants to actively absorb moisture during transit.
• Use humidity indicator cards to determine when products have been exposed to moisture and humidity above recommended storage levels.

Considerations When Selecting the Right ESD Packaging

Choosing the right ESD packaging for your products or applications requires careful consideration.

Start by assessing the static sensitivity of your components as this will guide the level of protection required. Having detailed specifications ready when consulting with your supplier ensures a more accurate and effective solution.

Thorough testing of any packaging option is essential before full-scale implementation to verify performance and compatibility. Beyond protection, consider factors such as design, cost-efficiency, and environmental impact. While low-cost solutions may seem appealing, they can result in increased damage rates, offsetting savings and potentially affecting customer satisfaction. In contrast, reusable ESD packaging may involve a higher upfront investment but often delivers lower lifetime costs.

Finally, evaluate the recyclability, waste output, and reusability of your chosen packaging to align with sustainability goals and operational efficiency.

Contact Us

If you would like more advice on ESD packaging, please get in touch with us on 01793 511000, sales@bondline.co.uk, or fill in the form below.