Packaging Science
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Data-Driven Testing, Design & Validation Services
ISTA-certified packaging science testing replicates real-world transport conditions—impact, vibration compression—to ensure packaging performs safely in the field.
From SolidWorks crate modeling to Pallet Design System engineering, our package science team delivers custom solutions that balance cost, strength and safety.
What Makes Millwood’s Packaging Science Different?
Since 1985, customers have trusted Millwood to go beyond pallets, investing in science-backed methods to protect their shipments and their people. Packaging isn’t just about containment — it’s about data, testing and proven performance. Our Packaging Science team blends engineering expertise, advanced modeling and real-world validation to deliver packaging that performs safely, efficiently and sustainably.
From SolidWorks crate modeling to full-scale ISTA-certified lab testing, every design is supported by measurable data and simulation. Using the Pallet Design System (PDS), our engineers test deck boards, stringers and load patterns in real time to ensure each design meets precise performance requirements before production. Whether refining an existing system or developing a new one, Millwood focuses on solutions that are balanced, cost-effective and right-sized for each application.
Millwood’s packaging science services provide:
- Validated Results through ISTA-certified testing labs that replicate real-world conditions and eliminate guesswork.
- Custom Engineering using advanced software modeling, SolidWorks and PDS simulations for precise, application-based designs.
- Cost Savings by eliminating over-packaging, preventing product damage and optimizing material performance.
- Sustainability through right-sized designs that reduce waste, conserve resources and align with stewardship goals.
When you partner with Millwood, you gain more than a testing lab — you gain a strategic packaging science partner dedicated to preventing failures, improving safety, reducing waste and protecting your supply chain from start to finish.
The Millwood Lab and Design Services form the foundation of our Packaging Science division — where data, testing and engineering come together to deliver packaging performance with measurable results.
3 WAYS MILLWOOD MAKES PACKAGING SCIENCE EASY
We Listen & Understand
Every operation is unique. We take time to understand your products, loads and goals before designing packaging that fits your application exactly.
We Test First & Prevent Failures
Designs are validated in our ISTA-certified lab to verify performance before production. We eliminate under-engineering that causes failures and over-engineering that wastes materials.
We Deliver Consistently
With a nationwide network of facilities and partners, Millwood provides reliable packaging solutions that perform consistently from one location to the next.
Leveraging Our Experience to Serve You
We understand that customers rely on Millwood for packaging solutions that combine precision, reliability and measurable results. Since 1985, our commitment has been to serve supply chains of every size with engineered solutions supported by these three guiding principles.
Source and Supply
With 37 strategically located manufacturing and repair facilities, 250+ strategic partners across North America and 1.5 million square feet of manufacturing and distribution space, Millwood controls its supply chain from the forest to the finished product. We handle more than 200,000,000 pallets and process over 100,000,000 board feet of lumber per year. Our vertically integrated operations ensure quality and reliable supply for our customers.
Exceptional Service
Serving others is our highest aim. Our dedicated customer support team delivers personal attention, not automated replies, with the care, integrity and expertise you deserve. We prioritize people by listening to your questions and concerns to provide the best support. When you connect with Millwood, you can expect an experience marked by professional care and genuine responsiveness. Trust us for consistent, customer-focused service that truly exceeds your expectations.
Sustainable
Operating under a culture of Perfect Stewardship, Millwood is committed to efficiency without compromise to our environment. From the way that our trees are harvested to our innovative line of sustainable packaging products and numerous recycling programs, we will work with you to reduce waste and meet your sustainability goals. Partner with us for sustainable solutions that support your business while protecting our planet.
Providing Comprehensive Packaging Science Solutions That Scale as Your Business Grows
LET’S BUILD TOGETHER
Building strategically with Millwood means having a partner who can grow with you—no matter your size or goals. Whether you’re operating two locations or two hundred, choosing Millwood is a smart move because we are built for scale. We serve some of the nation’s largest brands and know how to support growth at every stage, from startups expanding rapidly to industry leaders adding facilities nationwide. That scalability ensures your packaging and pallet supply stays reliable and efficient as your business evolves.
We make scaling simple because we understand multi-location needs and service them with one integrated solution. Our nationwide reach and proven processes mean you don’t have to manage different suppliers for each region—we take care of it all. When time is critical and your business is growing fast, our ability to deliver consistently, at scale, across multiple facilities makes us a strategic partner you can count on.
Millwood is more than a pallet supplier—we’re a one-stop packaging solutions partner. From pallets to load securement, recycling solutions and strategic sourcing, we help optimize your supply chain and support your sustainability goals. Whether you buy 500 pallets a month or 5 million, we have the infrastructure, expertise and flexibility to scale with you. Partnering with Millwood means you gain a reliable ally who helps you focus on your growth while we handle your packaging needs.We would look forward to talking with you to see how we can help serve you.
As part of our Load Securement & Protection product line, Millwood’s Corner Protectors are designed to protect products from dents, strapping abrasions and shipping and handling damage.
Millwood Lab
Our ISTA-certified test lab gives customers confidence that their wood pallets and packaging solutions will perform in real-world conditions. By simulating shipping and handling environments, we test, verify and optimize designs to reduce product damage, minimize waste and improve supply chain efficiency.
PalletView
Track the quantity and condition of various managed assets such as pallets, tier sheets, plastic dunnage and airbags with PalletView, our proprietary web-based application.
Pallet Recycling
Millwood offers complete pallet recycling programs to retrieve, inspect, recover and remanufacture or repair pallets. Our recycled pallet and recovery programs include green recycling processes that complement corporate sustainability initiatives.
See How We've Helped Others
When a leading restaurant brand discovered a packaging error just weeks before launching its new automated distribution center, we acted fast. Working alongside their engineering and operations teams, our Packaging Science Lab redesigned, tested and validated new pallet configurations to keep the project on schedule.
Through collaboration and verified design, we prevented product loss, protected their investment and ensured the launch happened on time.
- Developed and tested three verified pallet designs under tight deadlines
- Prevented loss of 136,000 boxes of product per rotation
- Enabled an on-time launch with zero delays
Reliable. Available. Local.
We understand it is important to know that your pallets will be delivered on time, every time. That's why we are where you are.
Frequently Asked Questions
Packaging science uses engineering, data and testing to design packaging that performs safely, efficiently and sustainably. It validates each system before it reaches the field, reducing risk and protecting your products and people.
Millwood’s Packaging Science division combines SolidWorks design, Pallet Design System modeling and ISTA-certified testing to verify performance under real-world conditions. Our data-driven approach helps companies prevent failures, control costs and enhance supply chain confidence.
ISTA testing confirms that packaging can withstand the vibration, impact and compression it will encounter in transit. It turns assumptions into proof and gives you quantifiable assurance of performance.
Millwood’s ISTA-certified lab simulates real-world shipping scenarios to detect weaknesses before production. This testing reduces damage claims, improves safety and saves time by validating designs in advance.
Design determines strength, stability and efficiency. Using SolidWorks and the Pallet Design System, Millwood digitally models and tests crates and pallets to predict how they’ll perform under load.
This process identifies the optimal balance between durability and material use. It ensures you get packaging that is safe, compliant and cost-effective without over-engineering or excess waste.
By replacing trial-and-error with data. Packaging science eliminates over-packaging that adds weight and under-engineering that causes breakage.
Millwood’s testing and analysis identify exact performance requirements so materials are used efficiently. This balance reduces replacement spend, product loss and total cost of ownership while improving supply chain reliability.
Any industry that ships heavy or fragile products — from building materials and industrial machinery to aerospace and automotive — can benefit from packaging science.
Millwood custom-engineers each solution based on weight, handling requirements and risk factors, ensuring protection and efficiency across diverse operations.
By optimizing material use and designing for longevity. Right-sized packaging reduces waste and carbon footprint while maintaining strength and safety.
Millwood integrates recycling programs and sustainable materials into every design. Our Perfect Stewardship culture ensures each solution advances both operational efficiency and environmental responsibility.