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Returnable vs. Expendable -Returnable packaging is more expensive from an initial investment standpoint but potentially savings could outweigh this fact. Overall for returnable packaging to be used, the proper flow must be determined.

 

Characteristics of the product- Weight, shape etc. The more information related to the product itself will allow packaging designers to analyze how alternative materials will act when in contact with the product to avoid scratching, vibrations, and much more.

 

The value of the product - If it is a valuable product then it probably needs more secure material. Hence why a percentage of the product value should go toward a packaging solution vs. a standard dollar amount, disregarding the products worth.

 

The fragility of the product - A more fragile product needs more protection. This is when material handling and transport modes are considered in order to avoid rough handling and when inner packaging is decided. 

 

Product requirements -Every product has a unique need. All factors of your product and its handling are needed in order to build the optimal solution. In doing this your product is separated into different packaging groups. Considering this allows packaging solutions which were designed for alternative products with similar characteristics and when needed, the beginning of a customized packaging solution.

 

Cost -“Packaging should save more than it costs” – Tetra Pak. It’s easy to point and say ‘x’ doesn’t equal ‘y’… but when you factor in all scenarios the end result is all that matters.

 

Stackability - Certain materials and packaging can be stacked on top of each other easier than others. Understanding how you plan to transport and store the packaging/product will help identify the need for additional support or material strength.

 

Material Handling- Ease of handling sounds simple, but many factors must be taken into account. How you handle the package in your facility doesn’t necessarily mean your end customer does the same way. Here we must consider if pump trucks, fork trucks, slinging, etc will be used, since re-enforcing the pallet may be the best solution.

 

Ergonomic demands- Packing products into containers sounds easy... but to do it in an optimized way and safely is a bit more tricky depending on the packaging solution itself. You should always look into how you can pack products into the outer packaging without too much bending (especially with heavy products or packaging).  

 

Test, test and more testing - So you think you have a suitable/optimal design. Has everything mentioned above been considered? Great.. has it been tested? This is one of the main areas companies overlook. They purchase packaging and enter it into their flow. Imagine what your end customer thinks when products arrive damaged etc due to a miscalculation somewhere. Test, test and test again to ensure your positive image with your customer is kept longterm.

 

Environmental Concerns - Some packaging materials are easier to recycle than others. Other materials have a smaller carbon footprint in their creation. Do you know what effect your packaging has on the environment?

 

In some situations it’s of the essence to know if the packaging chosen for a specific item will be enough. In this case a FEM Analysis can be used (which is a simulation tool) to show what forces the product will obtain and if provisions have to be made.

                                           

This graph shows the optimal packaging design (e.g. the lowest cost and lowest packaging grade for a specific item). So when packaging is chosen increasing the packaging grade slightly has very little effect on the cost of the packaging, in return we get a better product protection which leads to reduced risk of damages and happy customers.  However… as shown in the graph, increasing it too much leads to an over-packed overpriced item.