Packaging Design Checklist

Packaging Design

When designing a package, be aware that it serves four basic purposes in distribution of goods from source to destination.

1. Goods must be contained thoughout the distribution process.
2. Contents of the package must be protected from the hazards in distribution for safe arrival at destination.
3. Packaging should assist in other ways to facilitate distribution and use of contents, including ease in handling, storage, transportation, and unpacking.
4. The package must communicate required information, including contents, destination and any special handling warnings.

For transport packaging, the designer should achieve the following objectives during the design process:           

• Product protection from all distribution hazards
• Use of environmentally responsible materials and systems
• Minimizing shipping costs, effective use of space in transport vehicles
• Ease of handling and storage in distribution
• Efficient use of labor in packing
• Meeting customer needs

Packaging Design Process

There are certain steps in transport package design that should always be included.

These are as follows:

1. Be knowledgeable of the product characteristics- Fragility with respect to shock and vibration; ability to hold compressive loads; susceptibility to corrosion or abrasion; as well as dimensions and weight.
2. Obtain marketing and distribution requirements- Knowledge of possible transport modes, types of distribution systems, potential customers, quantities required per package, expected daily and annual volumes, etc.
3. Determine what hazards may occur in distribution- Any or all of these may occur during one shipment- rough handling, compressive forces, vibration in transit, high humidity, temperature extremes,   concentrated impacts, puncture impacts, high altitudes, etc.
4. Evaluate potential alternatives for both packaging and unitizing- avoid considering only those methods or materials presently used; evaluate others used successfully in the industry.
5. Design the shipping container, interior packaging, and unitizing (if required)- Starting with information from the above research, one can scientifically design transport packaging by utilizing information from suppliers, textbooks, and further research for technical data on each component of the packaging system. Standard tests such as shock, vibration, compression should be conducted to identify any weaknesses and improvements required during the design process.
6. Check the adequacy of packaging by performance testing- When the design is completed, subject the transport package to a performance test consisting of a sequence of anticipated hazards/tests in the laboratory. ASTM D4169 is highly recommended along with ISTA Series 3 procedures.
7. Be prepared to redesign if the performance test fails- Even experienced engineers may find their design has failed the performance test, and a redesign and retest is required.
8. Consider redesign of the Product if performance tests fail- Sometimes it is more expedient and less costly to redesign the product as a means of passing performance tests, rather then adding cost to the packaging.
9. Methods of packaging are needed- Methods of packing products in transport packages and of arranging the packages in unit loads should be developed. Complex multi-piece packaging requires documented methods for correct and consistent packing. Sometimes redesign of the package is required to optimize overall cost of materials and labor.
10. Documentation of the above is essential- Specifications of packaging materials and unitizing should be documented, and also packing methods and testing results.

When packaging design is completed, as detailed above, it is a good idea to check once again to assure that nothing has been overlooked. Here is a suggested CHECKLIST to use before implementing the plans.

• Has the design been performance tested using industry standards or regulatory requirements?
• Has sustainability/environmental responsibility been determined?
• Have all distribution cost factors been considered- handling, storage, transportation, etc.?
• Were returnable or reuseable containers and dunnage considered?
• Have all rules and regulations applying to distribution of the product been  checked and the design determined to be adequate?
• Evaluated all possible alternative materials and methods?
• Checked damage and customer complaints for the product line?
• Employed industry standards for materials and design criteria?
• Compared cost of this product package versus average for similar products?
• Documented the design in the company’s specification system?

* The following material was provided by Al McKinlay a Transport Packaging Consultant and may have been edited for your general use. Mr. McKinlay has worked in the area of transport packaging for over 40 years. His wealth of knowledge is appreciated by many in the industry.

To read more about Al McKinlay or transport packaging, please visit his website at www.transport-packaging.com.