Package Design for Fragile Products

Through our 50+ years of research and commercial project work in our Distribution Package Testing Laboratory, Smithers Pira has developed a wealth of expertise in technical pack design. Our commercial focus combined with our technical expertise positions us to understand the requirements of foam and corrugated cushion design, cost minimisation, cubic volume optimization, product fragility requirements and elimination of damage.

In Smithers Pira's experience, savings in packaging cost and cubic shipping volumes can be delivered through technical packaging design by understanding product damage vulnerability and balancing this against the hazards of distribution. This is also in alignment with the requirements of sustainability. Effective packaging design can also reduce the cost of returns and high costs associated with field service and repairs. We also understand that over-packaging is not a 'quick fix' solution: over-packing, or inappropriate packaging, can cause as many problems as it attempts to resolve and causes an unnecessary cost burden.

Historically Smithers Pira's focus has been on cushioning design and corrugated performance/specification for fragile and vulnerable products. More recently projects have included design of thermoformed trays and cartons for medical device products, and design of rigid plastics consumer goods packs where specific attention to distribution and handling was required.

Smithers Pira's Strengths in Technical Pack Design

A key factor in our approach is to take a whole supply chain view when it comes to developing packaging systems. In this way we ensure that packaging change and savings in one area are not implemented at the expense of additional cost in another.

In addition our independence allows us to design and select materials freely without bias from suppliers or bias towards specific material types or pack formats.

Commonly our design process includes:

• Review of requirements/setting the brief
• Concept development
• Evaluation of concepts against key performance criteria
• Costing most attractive solutions
• Prototype sourcing or sample development
• Testing and trialling either in the field or in our package testing laboratories
• Review and final selection/specification.

For complex assembled goods (machinery, electronics, medical devices) consideration includes product fragility assessment, evalaution of expanded foam solutions by cushion curve analysis, and vibration resonance characterisation.

For corrugated board, Smithers Pira's design and specification work takes account of key real life issues including effects of climatic conditions (high humidity), duration of warehouse stacking or container/pallet shipment, stacking pattern/arrangement, mixed loading and extended supply chain handling.