In global trade, packaging is usually seen as something practical. It protects goods, keeps shipments stable and helps products move efficiently from one place to another. What is less often considered is that packaging itself can introduce risks. Not visible risks, but ones that build up quietly over time. One of those risks is formaldehyde.
Formaldehyde is widely used in supply chains around the world, yet many companies are only partially aware of how it behaves in real transport conditions. To better understand this, we spoke with Kevin van Tienen, Safety Expert, who works closely with containerised goods on a daily basis.
What is Formaldehyde & Why is it Used in Packaging?
Formaldehyde is a chemical substance with a strong, recognisable smell. It is mainly used in the production of resins and adhesives, especially in wood-based materials. In practice, the reason is quite straightforward.
“It’s strong, relatively cheap and cures quickly. That makes it very suitable for large-scale production,” says Kevin van Tienen.
Because of these properties, formaldehyde in packaging is more common than many people expect. It plays a role in materials that are used every day in logistics operations.
Where Formaldehyde Appears in the Supply Chain
Formaldehyde is most often found in:
- Wooden pallets, particularly plywood
- Particleboard and other composite wood materials
- Adhesives used in packaging
Within container logistics, formaldehyde exposure is frequently linked to shipments that include wooden pallets. In some cases, concentrations are noticeably higher than expected.
For that reason, it is sometimes referred to as “chipboard gas”, a term that reflects its connection to engineered wood products.
How Formaldehyde Builds up During Transport
Formaldehyde does not remain contained within materials. Over time, it is released into the air through a process known as off-gassing. In open environments, this may not immediately lead to high concentrations. But inside a shipping container, the situation is different. Containers are enclosed spaces with limited ventilation. During long journeys, temperature and humidity can increase, which accelerates the release of formaldehyde.
“What we often see is that concentrations build up during transport. By the time a container is opened, the levels can be significantly higher than people expect,” says Kevin van Tienen.
This is what makes formaldehyde in containers particularly relevant. From the outside, nothing seems unusual, but the air inside can tell a different story.
Health Risks of Formaldehyde Exposure
The risks associated with formaldehyde are not always immediately visible, but they are well documented.
Short-term effects
According to Dutch public health guidance (RIVM), inhalation of formaldehyde at higher concentrations can irritate the eyes and airways and may cause short-term symptoms such as headaches or dizziness.
Long-term risks
While the mechanisms are complex, long-term studies suggest that repeated exposure to formaldehyde, including at low concentrations, may be associated with elevated cancer risk. The International Agency for Research on Cancer (IARC), as cited by the Dutch National Institute for Public Health and the Environment (RIVM), classifies formaldehyde as carcinogenic to humans (Group 1).
For workers in logistics, especially those who open and enter containers regularly, this creates a situation where exposure can occur repeatedly.
“You cannot rely on smell alone. By the time you notice formaldehyde, the safe limit may already be exceeded,” says Kevin van Tienen.
It is also worth noting that formaldehyde can continue to off-gas for a long time. In some cases, this can last months or even years, meaning exposure is not limited to transport alone.
Why Formaldehyde Risks are Often Overlooked
One of the reasons formaldehyde in packaging is often underestimated is that it does not fit the typical image of a hazardous material.
Companies tend to focus on clearly labelled dangerous goods. Packaging materials such as pallets or wood products are rarely seen as a source of risk.
“Pallets and packaging are often seen as harmlesss. In reality, they can still contribute to gas exposure,” explains Kevin van Tienen.
At the same time, global supply chains introduce variation. Materials come from different regions, with different standards and cost considerations.
Even when products meet emission standards, those tests are carried out under controlled conditions. Real-life transport environments are rarely the same, which can lead to higher formaldehyde levels in practice.
Measuring Formaldehyde in Containers
Detecting formaldehyde is not always straightforward.
Many commonly used gas detection methods do not measure formaldehyde accurately, especially at low concentrations. Smell is not a reliable indicator either.
This is why measurement plays such an important role.
Kevin van Tienen explains:
“Measuring is knowing. You need to understand what is actually present in the container at that moment,”
Advanced equipment, such as FTIR analysers, can measure formaldehyde alongside hundreds of other substances within a short time. Timing is essential. A container that was measured earlier in the supply chain can still develop higher concentrations during transport. That is why formaldehyde testing should always take place immediately before opening or entering a container.
Reducing Formaldehyde Risks in Practice
Managing formaldehyde exposure starts with understanding where it originates. From there, companies can take practical steps to reduce risk.
The most effective approach is to address the source.
“If you can replace materials that contain formaldehyde, that is always the best solution,” says Kevin van Tienen.
There are alternatives available, such as:
- Formaldehyde-free pallets
- Slipsheets
- Other load carriers made from alternative materials
At the same time, these decisions are often influenced by cost and availability. Especially in large-scale operations, even small differences can have a significant impact.
This makes cooperation within the supply chain important. Suppliers, logistics providers and importers all play a role in reducing formaldehyde exposure.
In practice, companies that manage this well tend to follow a structured approach. They start by measuring, build a data history and use that information to carry out risk assessments.
Over time, this allows for more targeted monitoring, rather than applying the same level of control to every shipment.
A Growing Awareness of formaldehyde in Global Trade
Formaldehyde in packaging is not a new issue, but awareness is gradually increasing.
More companies are starting to recognise that formaldehyde is not just a theoretical concern, but something that can influence daily operations in logistics and warehousing.
At the same time, it remains a relatively quiet topic.
“Once you start looking for it, you realise how often it appears,” says Kevin van Tienen.
For many organisations, that realisation is the starting point. Not for immediate large-scale changes, but for a more informed way of working. One where formaldehyde risks are better understood, measured and managed over time. In a supply chain that continues to evolve, that kind of awareness makes a real difference.
Looking at Your Own Situation
For companies working with international shipments, formaldehyde is not always visible, but it can still be present in daily operations.
At Customs Support Safety, we help organisations gain insight into these risks through gas measurements, risk analysis and practical safety advice. This makes exposure visible and helps create a safer working environment.
If you would like to understand how formaldehyde may play a role in your supply chain, it often starts with gaining the right insight. Contact us to discuss your situation and explore the next steps.