Mil-Spec Packaging vs. Commercial: What's the Difference?

Safe and reliable transportation is a key ingredient to the success of all industries. Everything either moves on a truck, train, plane, or boat (or all of the above). One of the leading causes of loss in all industries lies in packaging and transit; every year, around $163 billion is lost in the global supply chain due to transit issues, expiration, and sometimes just bad packaging. 

Packaging seems innocuous enough, right? You just package up your stuff and ship it. 

It is a lot more nuanced than that, especially when the customer is the Department of Defense (DoD). There are differences between MIL-Spec and commercial packaging, and we are looking at them, so keep reading!

What is Mil-Spec Packaging?

When the military moves, it goes big. We’re talking about entire brigades of soldiers (3,000-5,000 troops) or even divisions (10,000-15,000 troops). The personnel alone are staggering, but that is just scratching the surface. A division has hundreds upon hundreds of trucks, trailers, and all kinds of other things. 

These all have to be shipped. 

https://www.dla.mil/Logistics-Operations/Packaging/#marking

Of course, it isn’t always this dramatic. Most of the time, MIL-spec packaging is not dealing with massive troop movements. It is a leading edge for the horizontal stabilizer on a jet. Or it is a rebuilt turbine engine for M-1 Abrams battle tanks. 

The military ships millions of items. Think about the sheer number of military installations: even a small-ish Air Force base has upwards of 5,000 Airmen in the Wing. Wings of heavy jets (tankers, bombers, airlift) generally have thirty to forty jets assigned. The amount of logistics involved in just one wing of jets is staggering. 

MIL-spec packaging is just as it sounds. The Department of Defense and other military organizations employ a set of standardized codes and requirements known as MIL-SPEC packaging. The codes specify the specifications, rules, and testing methods for different tools, materials, and operations utilized in military applications.

Advantages of Mil-Spec Packaging

Almost everything we have collectively learned about logistics and shipping has been through trial and error. Most of the lessons learned came during World War II's massive logistics operation. That war brought on many things, most notably the fastest technological advances the world has ever seen, but logistics were the show's unsung heroes. 

Throughout the war, the United States shipped tens of millions of tons of cargo and equipment across the Pacific and Atlantic, and in the process, lost a lot of material and men. Out of World War II came much more exacting and strict standards, the modern evolution laid out in MIL-STD-2073-1.

A lot of the most common logistics and shipping methods we see today are a direct result of lessons learned in World War II and solutions created directly for the DoD. These include intermodal containers (which are the standard method of shipping everything transoceanic, Tricon and Quadcon containers, and a lot more.  

The main advantage of MIL-spec packaging, outside of it being a requirement for most DoD shipments, is that the systems and methods used are rigorously designed to withstand the harshest travel in the world. Oh, and MIL-spec packaging is built to work around dimensions used everywhere. If you follow MIL-spec, it will fit on any standard shipping platform. 

An Overview of Mil-Spec Packaging Codes

Alright, so we know that MIL-spec is the benchmark standard of logistics packaging for the entire U.S. military and is defined in both MIL-STD-2073-1 and MIL-STD-129. 

Some specific packaging codes are standardized across the DoD through the MIL-STD-2073-1. These are generally called category codes. A cat code is a four-digit code used to concisely and quickly identify the contents of the packaging. Each digit has a specific meaning. There are three categories, and the first two digits are for category #1: physical and chemical characteristics. 

For instance, there are four separate category codes for iron and steel products alone, depending on two key characteristics (“Is a contact preservative allowed,” and “does the item have critical surfaces or application?”). 

The next part of the code, the third digit, is found in Table A-II: the weight/size/ and non-operational fragility category code determination.  

Finally, the third packaging code, found in Table A-III, is the contact preservative category code. These are the many different preservatives used on the myriad items shipped, and protective preservatives are needed to stay clear of rust and other contaminants. 

A great example of this is cosmoline on small arms, which would be category code D. This waxy grease film is applied to all rifles shipped overseas to ensure they arrive rust-free. 

What is Commercial Packaging?

Ok, we have broken down MIL-spec packaging and looked at the different category codes. 

What is commercial packaging?

First, when we talk about commercial packaging, there are two distinct types of packaging geared toward the private sector: commercial and industrial. Commercial packaging is packaging geared toward the consumer and is used for retail. It is generally the face of the brand, so the main purpose of commercial packaging is to be visually appealing. 

A great example of this is Bicycle playing cards. The boxes are simple but iconic. The brand image is always recognizable. This is commercial packaging. 

On the other hand, industrial packaging relies heavily on corrugated cardboard, plastics, and other durable materials. Industrial packaging is not focused on aesthetics but instead focuses on keeping the contents secure and safe throughout the shipping process. It must be adequately sized to ensure it is universally shippable, easily loaded, and unloaded on standard trailers and intermodal containers. 

Differences Between Mil-Spec and Commercial Packaging

Military equipment and its shipping are broken into two categories, as defined in MIL-STD-2073. 

The first are items that are either not entering military distribution systems or aren’t mission-capable. These do not fall under the requirements for MIL-spec packaging, so standard packaging is acceptable. 

However, items that enter military distribution systems and put into long-term storage, or more importantly, items destined for wartime and frontline use, must be packaged per MIL-spec packaging standards. 

The differences are too numerous to list here, but MIL-spec packaging is a standard that requires robust packaging practices, often using wooden crates or even metal composition. Commercial and industrial are focused on using the least resources possible while being just durable enough to get the materials to the destination. 

Why Businesses Might Prefer Mil-Spec Packaging?

So, why would a business need MIL-spec packaging? There are a few reasons. 

First, if the products you are supplying or the customer receiving them require MIL-spec packaging−if a product or a customer requires it per regulations, you must ship it accordingly. 

But if it is not required, shipping MIL-spec still makes sense for many reasons. 

1. It is more reliable. The DoD created MIL-spec packaging to embrace the harshest conditions on earth. If it gets safely to the battlefields of Iraq, it will make it to North Carolina. 
2. It is standardized. MIL-spec is built on total standardized sizes and parameters that are followed everywhere. You know that when you follow MIL-spec, it fits. 
3. One of the central tenets of MIL-spec is to use large, full containers. This maximizes shipping efficiency on your end, so you can use fewer individual packages. Less individual packages reduce the overall space required and save both money and time.

How Does Mil-Spec Packaging Affect Your Business?

If your business deals with physical products, you are interested in protective packaging. But not all protective packaging is made the same. It doesn’t all provide the level of protection needed for your intended mission. 

Commercial/industrial packaging is not designed for durability. It is designed to meet the minimum durability standards to arrive at the destination intact. 

On the other hand, while MIL-spec will cost more upfront, it is designed to be the most reliable logistical process on the planet. On the backend, you will likely see savings because of the sharp reduction in loss. 

It is not uncommon now to find internationally recognized logistics giants adopting U.S. MIL-spec packaging standards because of the guarantee of quality and great historical success of the standards. Look no further than the rapid deployment of troops during Operations Enduring and Iraqi Freedom to see the success of MIL-spec packaging in action. 

How Greenwood Aerospace Can Help With Mil-Spec Packaging

Greenwood Aerospace is an old hand at MIL-spec packaging, with over forty years of experience in the field. We are here to handle your company's MIL-spec packaging needs. 

Contact us to learn more about our MIL-SPEC packaging services. Are you looking to expand your operation? Learn about how you can become a supplier with Greenwood Aerospace. Reach out to us at contact@governmentprocurement.com to learn more about what Greenwood Aerospace can do for you!

Also, for large sales, reach out to us at sales@governmentprocurement.com, and we’ll go over all the options for your business!