Packaging plays a critical role in assuring your product reaches its end-user in the condition in which it left your facility. The style and design of packaging can have an impact on packaging line efficiency, and the package size, design, and materials can also drive costs and directly impact the level of product protection.
A packaging assessment can determine where inefficiencies create unnecessary risk and costs. A packaging assessment should be done annually, when a new SKU is introduced, or when feedback comes from the end customer highlighting a need. The assessment will focus on creating cost savings, increasing efficiency, and ensuring a positive representation of your brand.
What Does a Packaging Assessment Involve?
A packaging assessment provides an opportunity for your packaging supplier to get to know you and your unique needs. Since no two manufacturers are alike, their packaging needs will differ based on the products they sell and their distribution environment.
A packaging professional will evaluate your needs based on each product for material selection, optimization, and logistics and supply chain management. In some instances, there may be an opportunity to combine SKUs with minimal impact on the product but allow for volume pricing.
Material Selection
Determining the correct material or combination of materials to use for a particular solution will be the first step. Some of the factors that influence the material choice will be:
- Shipping and storage – Stacked Pallet boxes/items must bear the weight of the products on top of them both in storage and in transit. Smaller consumer products are generally shipped in corrugated boxes because they are lightweight and make shipping less expensive. Large pieces of equipment shipped on a flatbed truck or stored outside need durable packaging, such as weather-resistant wooden crates and potentially moisture-protection bags and desiccants.
- Product size and weight – The packaging must contain the item and not fall apart because it can’t bear the weight when picked up.
- Product fragility or durability – Fragile items and those requiring special protection, such as highly polished finishes or optical lenses, often do well with non-abrasive foam inserts that cradle the product to protect it.
- Product cost– Investing in highly protective packaging for inexpensive items isn’t cost-effective. In contrast, it makes sense for valuable and expensive items.
- Environmental impact – If eco-friendly packaging is a priority, you have options with paper-based packaging, wood packaging, reusable plastic, and recyclable foam.
- Packaging budget – The solution must fit within your budget.
Packaging Optimization
The packaging will be optimized to fit the product and, when required, increase your production line’s efficiency. To meet both may require a compromise. Some of the factors that will be evaluated include:
- The number of products ideal for each package – This could be based on how they are delivered (direct to consumer, retail store, distributor, etc.), optimization of parts per pallet, and packaging line efficiency.
- Efficiency – Packaging types that eliminate steps, such as gluing and taping within packaging lines, might be considered. In addition, box assembly (including using additional inserts and dividers) should be optimized for efficiency during product pack-out. Boxes and packaging lines that are designed for ergonomic efficiency and a packaging process flow that has been optimized can help increase production throughput.
- Minimization of materials – The packaging should fit the product with minimal excess space, allowing for internal packaging materials to be minimized. The packaging must be sufficient enough to adequately protect the product against impact and vibration while reducing materials.
- Wrong packaging style – Beyond choosing the right materials, the right type of packaging is needed. Corrugated boxes, for example, come in various styles, such as regular slotted containers, self-erecting die-cut boxes, or telescoping. Similarly, wood provides many options, such as full crates, wooden bases, pallets, and more. Plastics can be molded into a variety of styles, from open trays to totes and cases.
- Prototyping – A prototype can help ensure the packaging meets your specifications before you invest in dies for larger orders.
Logistics and Supply Chain Management
A proper packaging assessment will also consider logistics and supply chain management. It doesn’t make sense to optimize packaging only to have efficiency loss and cost increases from supply chain issues. Some items that may be evaluated include:
- Pallet cube – This should be maximized for shipping and warehousing efficiencies and optimized for truck loading.
- Testing and validation – Testing, such as drop, vibration, and impact testing, should be performed as required to validate designs before theyare shipped.
- Storage environment – In the case of corrugated KD boxes, the temperature and humidity of the storage environment can impact the box’s strength. Your packaging partner can help you determine if yours is appropriate.
- Inventory carrying cost – Some partners will take the evaluation further. WIC offers vendor-managed inventory (VMI) programs to ensure packaging is available when needed and keeps on-hand inventory levels low.
TheWIC Approach
We use a solution-driven process to identify and implement a best-fit solution for your project, as well as uncover ways to reduce your total costs. We look at how your packaging impacts other cost drivers such as freight, labor, damage, safety and handling, reusability, and performance. Each project is put through a rigorous process that includes design review, modeling and simulation, prototyping, and testing and validation to ensure it has been optimized to reduce your risk and protect your products.
For even greater control of your supply chain, you can take advantage of our VMI program. We track your inventory needs, and whether you prefer a blanket order or a Kanban agreement, we can ship what you need when you need it.
If you are interested in a packaging evaluation, contact us for a consultation.