Case Studies
Innovative Packaging Solutions in Action
Explore real-world applications of our cutting-edge packaging designs and engineering, showcasing how we solve complex challenges and drive success for our clients across various industries.
Pioneers with Purpose
Challenge
Detect condensation problems in pizza flour packed in paper bags.
Solution
The project involved conducting temperature and humidity analyses at various stages of the distribution cycle. We identified that temperature differences caused condensation in relation to the dew point, confirmed by temperature chamber simulations replicating conditions at the production
line, warehousing, and during transportation. We proposed various alternatives including improving bag seals, using perforated stretch film, and adjusting transportation timings to avoid temperature peaks.
Results
We successfully identified the root cause of condensation issues and presented optimal packaging solutions to the customer to be able to significantly reduce product rejections due to humidity.
Corrugate Shipper Harmonization
Challenge
Optimize packaging for over 400 SKUs at a dedicated facility to achieve cost reductions.
Solution
We conducted a comprehensive review of all item documentation and specifications to identify optimization opportunities. We presented cost-effective solutions, developed engineering proposals, and provided necessary instructional materials. Our approach included reducing corrugate thickness from 32 ECT to 29 ECT, implementing generic printing, and transitioning from RSC cases to double bundle packs.
Results
Our solutions generated annual cost savings of $3.75 million and streamlined packaging processes across the board.
Vendor Localization and Packaging System Optimization
Challenge
Maximize the efficiency of shipping bulk packaging materials from the U.S. to Mexico.
Solution
We identified and qualified new vendors to replace imported materials, standardized packaging dimensions for better space utilization, and validated materials for long-distance shipping. This approach optimized the entire packaging system for our client.
Results
We achieved annual cost savings of $400K and significantly improved container utilization by localizing all packaging materials.
Package Damage Troubleshooting and Elimination
Challenge
Address frequent failures of packaging during the distribution cycle and improve the product/package ratio.
Solution
We analyzed the current packaging for various SKUs, benchmarked against competitors, and developed optimized packaging options that were aesthetically pleasing and feasible for manufacturing. We implemented the best options using rigorous testing protocols.
Results
The new packaging maintained consistent quality and reduced shipper weight by 20%, resulting in significant cost savings.
Corrugate Shipper Cost Reduction
Challenge
Reduce packaging and shipping costs in response to a spike in prices during the pandemic lockdown.
Solution
We redesigned the inner packing to decrease volume and optimized the palletizing to maximize container use. We also developed relationships with new suppliers for corrugated shippers.
Results
We reduced packaging material costs by 7% and freight costs by 25%, effectively decreasing the overall shipping expenses.
Packaging Optimization for Sustainability
Challenge
Reduce the grammage of hot fill and cold fill PET bottles to promote sustainability.
Solution
We conducted a structural redesign and analysis, creating optimized bottle alternatives. We coordinated with suppliers, executed line trials, and implemented the new designs.
Results
We achieved a 15% to 21% reduction in PET bottle weight, which led to significant savings on PET resin usage.
Packaging Equipment Integration and Validation
Challenge
Support new product launches by integrating and validating new packaging equipment for high-speed production lines.
Solution
We developed and executed comprehensive URS, FAT, SAT, IQ, and OQ protocols using tools like MS Project and AutoCAD for facility and equipment layouts. We also worked closely with equipment manufacturers to address design and commissioning issues.
Results
We successfully installed and commissioned three high-speed pouch filling lines, which are now running efficiently with six different SKUs and packaging configurations.