This paper presents the development and testing procedures for new packaging systems for papaya fruit. Papaya is a nutritious tropical fruit, consumed both in its fresh form and as a processed product worldwide. Thailand is a major exporter of fresh and processed papayas from Asia. Major quality indices for papayas include colour, size, firmness and freedom from defects and decay. A high percentage of post-harvest losses of papaya fruits have been reported as exports have increased. Mechanical damage is one of the major causes of the quality loss of papaya fruits, therefore, proper packaging is demanded for better protection. In addition, other criteria are important to meet consumer acceptance. New packaging systems for papayas were compared with the existing systems currently used for local markets. The packaging systems were evaluated in terms of physical protection, heat transfer characteristics for rapid cooling and maintaining optimum temperature and relative humidity during post-harvest, quality maintenance, and marketing issues. Two cushioning systems, foam nets and paper-based wrap materials, were also compared. Actual shipment and vibration tests were performed and the effect on quality was determined. The new packaging systems tested showed better protective performance and improved quality parameters, as compared to existing systems. Minimized mechanical injuries resulted in a decreased susceptibility to decay and bruising. Paper-based cushions showed similar protection to plastic foam nets materials but offered a better ripening response for papayas. The data were compared to seek an optimum packaging system for papayas based on the various criteria. Copyright © 2005 John Wiley & Sons, Ltd.