This study is done by the company Whirlpool of India Limited, situated at Ranjangaon MIDC, Pune. The company is facing the pr oblem regarding to packaging system. In December 2018, 265 Litre Whirlpool refrigerator product was found in damaged condition at e-commerce company amazon’s ware house. Dents were found on the door and outer wrapper of refrigerator. Also EPS protection were found in damage condition. Hence, this product has been blocked for selling by amazon Company. Also amazon is demanding for ISTA certification of above mentioned product for further selling process. After root cause analysis it is clear that EPS currently used is failing to absorb energy dissipated during impact. So, it is needed to select EPS (thermocol) with more strength, energy absorption capacity and cushioning effect and changes in packaging protection post. Strength of the EPS is mainly function of granular size, density, heating temperature and pressure of the steam. Mechanical properties of existing and new material will be compared after carrying out tensile test and compressive test as per ASTM standards. FEM analysis for structural testing has been done in ANSYS Workbench. © 2019, International Journal of Scientific and Technology Research. All rights reserved.