New Products and Unique Packaging

Sometimes the challenge is how to economically create custom packaging for a new and unique product and not break the bank doing it. In other words, protecting a product during shipment and making it affordable, even when the volume is relatively small. One way to do it is to combine stock and custom products rather than working with all custom items and eliminating some or the entire cost of dies and tooling.

Here are two recent examples:

Custom partitions and pads with stock RSC shipping boxes

Pente5 is a fast growing manufacturer of organic extracts which are all packed in glass bottles. They needed to create a four pack shipper case as well as a six pack shipper case for a new product launch.

We had no choice but to create custom pads and partitions for them but we intentionally designed them to fit two of our stock boxes. The finished product turned out great and we were able to avoid a higher cost custom box. This also minimized the amount of inventory they would have to buy and stock for their new product.

Custom inserts with stock die cut mailers

Spectrum Technologies is a manufacturer of weather monitoring devices and a good friend and neighbor. Their office is literally across the street from our facility and they asked for our assistance to create a three pack for a new, unusually shaped product.

We were pleased to discover our stock 9” X 6.5” X 2.75” die cut corrugated mailer fit the three products perfectly. Then all we had to do was design an insert that would immobilize the products during shipment. The insert fit perfectly into the stock box and the cost was minimized for the product and the tooling as well.

Green packaging solutions often require flexibility and creativity

There are many suppliers who sell only stock products and others who push everything into custom packaging but we see the advantage of combining the two whenever possible. We make green, custom packaging affordable and would like to help you with your packaging challenge.

Partitions have been rediscovered by the green and packaging communities as a great way to solve a packaging or damage problem, while reducing material and labor costs when compared to other product protection options. Best of all, it can all be accomplished with undeniably eco friendly, corrugated board.

Corrugated Partitions – Not Just for Liquor Bottles Anymore

Historically corrugated partitions have been a mainstay in the liquor and bottled beverage industry because they do such an excellent job of separating and protecting one product from another. Obviously bottle to bottle damage is virtually eliminated and other benefits are also enjoyed.

• Labels are not marred or damaged in shipment because label to label abrasion is prevented.
• Stacking strength is dramatically increased, even when the bottled and cased products are heavy liquids
• Bottles and jars remain upright, minimizing the possibility of leakers

New Applications for Eco Friendly Corrugated Partitions

Recently we have had a flurry of partition projects and applications and here are a few reasons why our customers chose this solution over other options we offered:

To verify count – Products were individually wrapped with Kraft paper to avoid damage and then randomly stacked and packed in a corrugated case. Our customer was being inundated by claims of incorrect counts. Coincidently the complaints were always for under shipment, never over, so we created a 20 cell partition that separated the individual products for easy, accurate count confirmation.

20 Cell Corrugated Partition

To minimize other packaging – We recently did a partition and shipping box design for products individually packaged in very attractive paperboard boxes. The partition kept them apart to avoid surface to surface abrasion but it also enabled our client to use a lighter weight box paperboard than originally planned. The partitions provided all the strength necessary to prevent the retail box from crushing so it looked great on the shelf. We were also able to design in a perimeter air cell to protect the product from the outside as well.

Corrugated Partition with Perimeter Air Cell

Any customers contemplating an increase in case thickness or grade because of shipping damage should consider partitions as a better and lower cost solution.

To satisfy a retailer’s request – In case you have not noticed, retailers depend on their suppliers to deliver product that is display ready. This created a problem for our client who was hand wrapping a semi fragile product in indented Kraft paper for cushioning and cleanliness. The retailer did not want their people to have to unwrap the products for display. Partitions solved the problem and increased our client’s sustainability score because many square inches of paper were eliminated.

Are “Built In” Partitions Right For You?

Many people do not realize partitions can be purchased pre-assembled but in some situations the space required for them may be an issue. One possible solution is utilizing a die cut box design that incorporates partitions. It is very possible an existing die can be used to avoid tooling costs, such as the jar/mug/candle box shown in the photograph below. There is no question that a design like this will be more expensive than a box with a separately constructed partition but it may not be as much as you think when you factor in all of the costs involved and depending on size, quantity, etc.

Built-in Partitions Ideal for Candle, Jar, and Mug Packaging

Corrugated partitions are just one of many solutions we offer and our advice to customers is always to consider the options before committing to the same, often ineffective and over priced solutions. Packaging products are constantly improving and many “old” solutions and designs are being re-invented to solve today’s difficult, green packaging challenges.

However, corrugated partitions can sometimes reduce overall packaging usage and unit cost, while providing a number of other important sustainable benefits.

• Partitions provide excellent product protection for small parts and fragile items such as coffee mugs. Reducing damage means reducing returns and replacements – which reduces packaging consumption!
• Partitions are easy to reuse if logistics support it. Heavyweight corrugated partitions can be reused many times over for intra-plant transport and sub-assembly applications.
• Partitions provide additional support inside the corrugated box, giving the shipping unit better crush resistance and overall durability. For that reason, using partitions may allow shippers to purchase lighter weight boxes, reducing overall corrugated consumption and cost.

For consumer-direct shippers, partitions have the added advantage of being customer friendly. Partitioned contents are as easy to unpack as it gets. Plus, the corrugated material is easy to recycle and can be reused for storage around the house.