The work aims to design the pallet unit load packaging system of vacuum flat glass sheets and conduct the drop simulation test to verify the reliability of the packaging system. A five-step method of transport packaging design was proposed and employed. The first step involved researching and gathering the relevant information of product and distribution environment. For the second step, the packaging solution was designed and modeled. With packaging materials such as corrugated fiberboard, plywood, ethyl vinyl acetate (EVA) foam, and strapping tape, 3D modeling was carried out by SolidWorks to establish the geometric models under various drop conditions. The third step was to establish finite element models. A suitable material model was selected for each packaging material, and the relevant performance parameters measured by experiments were used to conduct contact setting, meshing and load setting on the established geometric models The fourth step was to verify the reliability of the finite element models by conducting physical experiments and simulation tests, and comparing the results. The fifth step involved simulation tests under various working conditions, including drop, impact and vibration. The results of corner, flat and edge drop simulations were compared with the corresponding experimental results, with the maximum error smaller than 10%, which verified the reliability of the finite element models. The acceleration-time response curves of all glass sheets were obtained where peak acceleration was lower than the allowable one determined by the fragility of flat glass sheet, meeting the protective requirements. Based on the five-step method of transport packaging design mentioned above, the proposed packaging solution meets the protective requirements, which verifies the feasibility of the five-step method.