XQinnovations says that processes like printing and cutting corrugated card applies pressure and can damage the shear resistance of the material, reducing its strength and efficiency when it comes to packing produce or other goods.

"When people make boxes they tend to squash it and don't think this really matters as the corrugated board springs back, and the thickness recovers. But thickness is not a good measure of strength," technical director Russell Allan told AP-Foodtechnology.com.

"Instead, the shear stiffness, which measures how well the structure resists being pushed over onto its side, is a better test of what happens when boxes are packed and loaded," he said.

While some companies test the strength of the board by taking samples to the lab, XQinnovations has created a transportable tool that releases vibrations into the card. The frequency of vibrations is proportional to the shear stiffness.

"It's a way of getting to the shear stiffness without having to cut up the card," explained Allan. "You can just walk up to the board and test it."

The firm's research suggests that when paper leaves a corrugator it has lost an average 56 per cent of stiffness, and a box made from the card is 20-30 per cent weaker. This increases costs for end-users of the packaging, especially those requiring heavy-duty boxes.

"When a box fails, the supplier will add more paper and weight, making it more expensive," says Allan.

European packaging companies who are keen to reduce packaging to meet environmental regulations on waste have shown interest in the technology. In the US too, recent developments are expected to promote ways of reducing paper.

The world's biggest retailer, Wal-Mart, said in September that it would push its suppliers to cut the amount of packaging used by 5 per cent from 2008. The retailer, which has 60,000 suppliers, said it would recognize those suppliers who used less packaging and more effective materials.

"Although paper firms make sales based on weight, some are moving towards sales driven by performance," added Allan, formerly with Australian packaging giant Amcor.

"And this [new technology] gives them a chance to be leaner."

XQinnovation's Box Quality Measure tool costs about A$10,000 (€5,956) per unit but Allan promises that it will save around 20-30 per cent of paper in some applications.

One major packaging supplier has already introduced the tool company-wide, he said, and others evaluating it. Some say however that they have their own methods of assessing box strength.

Allan will present his findings and the new technology at the Food Solutions Expo in Victoria, Australia on 16 November. The firm is also looking into the efficiency of paper packaging.