AbstractThe main purpose of this study was to evaluate the effects of the cushion box and closed let‐down ladder usage in minimizing mechanical damage to corn kernels during free fall. Kernels from a single lot of cultivar KSC 705 were evaluated for percentage of breakage using three drop methods (free fall, with cushion box, and with closed let‐down ladder) at five different moisture contents (10%, 15%, 20%, 25%, and 30%), and three drop heights (5, 10, and 15 m). The results showed that the drop methods had a significant effect on the breakage sensibility of kernels. Sample kernels dropped without a ladder (free fall) had a significantly higher average percentage breakage of 13.80%. In the use of the cushion box, the average kernel breakage was calculated to be 11.41%, which was decreased by about 17% more than the free fall. Sample kernels dropped with the closed let‐down ladder had a lower average breakage of 7.26%, which showed that the closed let‐down ladder significantly helped to reduce mechanical damage to corn kernels by about 47% comparing free fall and by about 37% than the use of the cushion box. The amounts of kernel damage increased significantly with increasing drop height and decreasing moisture content, but the use of the cushion box and closed let‐down ladder systems somewhat reduced the adverse effect of the above factors. To minimize mechanical damage to kernels as they fall into the bin, a grain let‐down ladder should be installed in the bin so that it can receive kernels from the filling spout with minimum damage. Empirical models were developed for the dependency of damage to corn kernels due to the impact caused by free fall on the drop height and moisture content at different drop methods.