Daypacks That Survive Real Travel: Three-Year Field Test Results

I switch between several daypacks similar to how I switch between different pairs of running shoes. I put four different travel daypacks through their paces over the last 3 years and wrote down a list of what worked well for me and what didn’t. What worked well for me in terms of features and not in terms of branding.

This article is a field test without brands. It merely outlines the patterns that consistently emerged in various features of various packs. I merely wanted to outline the failure points and the points of success of different packs and hope that readers can apply that information to whatever brands they are considering.

When looking for a travel daypack it’s different than a daypack used for commuting. It needs to be able to withstand being thrown into an overhead bin, squeezed under seats on a bus, or at the bottom of a larger bag. A lot of weight will be packed into it – 5kg to 12kg or more – and it needs to have a decent profile for short hikes but also be able to be a city daypack for long periods of time. It will get dirty with rain, dust and sand and every now and then get dropped. It also needs to have good organization for things that you need to get to quickly like a passport and phone as well as stable storage for items like a laptop and a camera. Lastly, in a lot of parts of the world it’s best to blend in and not draw attention to yourself so the pack should look pretty normal and not highlight the expensive gear that you have inside.

Failed Features: Zipper Pulls and Slider Mechanisms. These are the cheapest components on a pack and therefore often fail first. Of the four travel daypacks that I have put through the wringer, three of the main compartment zippers’ slider mechanisms have failed within 18 months. The one pack with metal sliders that had sealed bearings, however, is still going strong after three years. That pack cost $40 more than the others but it has already saved me the cost of a new pack at 18 months.

Shoulder strap padding. Any padding is better than nothing but that said cheap foam is destined to collapse under heavy loads within approximately 200 days of constant use. Such straps are then unpleasant to wear as the thin, hard strap presses down upon the wearer’s shoulder.

Mesh back panels may look superior to solid material on advertisements and display packs, however they easily can snag a thread or hook. Prior to you realizing what occurred the hole will have enlarged into a huge tear allowing the foam backing of the pack to rub against your back. In addition, the area where the tear occurred will hold large amounts of sweat as well as odors that are no doubt harbored within the foam. Contrast that to a solid pack with panels of fabric that extend all the way to the bottom of the back and between the shoulder straps, featuring large vertical slots for airflow. This design may not breathe as well on warmer days but are far more durable and resist tearing completely.

Water bottle pockets with elastic only tend to stretch out after a year or so and, as a result, no longer hold bottles snugly. Often the bottle will suddenly fall out of pocket without warning. To design a side water bottle pocket that is going to last a long time, the elastic portion must be reinforced with a small drawcord that cinches the top of the pocket. It is not very hard to design such a side pocket and the reward is a great water bottle pocket that will last a long time.

However there are a number of features that can hold up for years. YKK zippers, heavy-duty bar tacks at all points where strap meet pack body, 1000-denier Cordura or better for the main body of the pack, solid plastic or metal hardware that has been pressure tested (these are usually printed with small specs and/or weights on the buckle), and internal frame-sheets that allow the pack to not collapse under the weight of the items packed.

Here are the price points for the daypacks I have used for the past three years or so, and how they held up over time. Keep in mind that these results should translate across brands, because the same parts fail the same way every time. As a general rule of thumb, if a pack costs less than $50, you can count on it to last a year or so, and then start to fall apart. Priced from $50 to $100, these will last 18 to 24 months, at which point various components will start to fail, but this is acceptable if you only travel from time to time. But for serious travelers, there is a certain point at which the additional cost of a better pack is outweighed by the improved durability and increased comfort. For me, that point is around $130. The difference between a pack in this price range and one that costs $200 or more is that the latter will be lighter, made of marginally better materials, but in terms of actual durability, the differences are negligible.

Some things I think should come as standard on travel packs. A padded laptop sleeve within the pack. A bottom compartment to stow trekking shoes or soggy items. Lockable zipper sliders on the main compartment. Flap style hip belt pockets which can be stowed away on the pack when not in use. Color – Travel pack tend to be worn in all weathers. So packs in neutral colors (gray, dark olive green, navy blue) tend to blend in with other travelers in budget destinations rather than making them stand out like a bright yellow or black pack.

Size: For general travel use 22-28 liters is usually plenty for most people. Under 22 liters you are not going to be able to fit in a packable jacket, a water bottle, a lunch and a small camera. Over 28 liters a pack starts to become very tempting to over fill with clothes and other items which can put a huge amount of strain on your back and cause the pack to become misshapen. My current travel daypack is 25 liters in size. It is perfect for me as it carries everything I need for a day of traveling. It also fits perfectly as a personal item under the seat in front of me on most flights. The pack has also held its shape perfectly over the last 3 years of heavy use.

Daypacks are a place to spend money. While you may find a sub-$50 daypack acceptable for a 5 day adventure, within 12 months the zippers will fail, the straps will wear and split. By the time it has failed you will have spent more than you needed to have and you will still need to purchase another. For serious travelers, the cost of a good daypack is spread out over three years or more of use. $120-180 is the “sweet spot” for daypacks in this class.