Fiber-based packaging has a lot of scope of innovation with materials, structure experience, branding and graphics. With innovation, there can come execution challenges both with structural and graphics. Generally, there are always some execution challenges with any project and they can be solved by some tweaking at the time of the production stage. Designers & engineers always keep some room for refinements during production. However, they sometimes can't foresee problems in the assembly line as most of the time it is a manual operation.
If in the assembly line a structural challenge arises it becomes a matter of worry as the design might have to go under re-evaluation. It may also require concept -refinement, re-engineering or re-work on artwork. This can affect timelines drastically and may involve another round of discussions and approvals from all stakeholders.
Customers prefer fiber-based packaging for the fast-paced project/launch as the product can come out in the market faster with less CAPEX involvement. This is possible because of the less complicated manufacturing process. With all consideration, there can be still unforeseen challenges on assembly lines that can affect the timelines. As most of the bundling and formation of packaging is a manual process.
CHECKPOINTS FOR REFERENCE
As designers & engineers have limited control at the production stage there can misalignments regarding designs and it might result in unnecessary escalations. Even though no one might have foreseen such challenges it becomes difficult for designers/engineers to explain the nitty-gritty of the initial project brief and keep everyone on the same page.
Designers & engineers can keep a few checkpoints in their minds while detailing the concept. Also, can help the client to understand the end result so that it does not come as shock to them if any challenges arise.
AVOIDING COMPLEX STRUCTURE
The packaging structure should be easy for non-skilled labor to understand. While ideation designers & engineers need to keep in mind that if the assembly is manual then the structure/KLD should be very easy to understand. If it is complex for warehouse staff to understand they might get reluctant or can form the wrong structure.
If the formation of packaging is not done properly it might get distorted during transit. For this matter, even the simplest of packaging structures can distort if the formation of packaging is done poorly. Poor packaging formation will affect consumer experience and brand image.
For face-paced project designers and engineers should always cross-check the capability of the vendor to form the packaging. This is very important to understand the capabilities of warehouse staff and how efficiently they will be able to grasp your design. Designers & engineers can also make videos of formation at their end to explain the design. This helps them to have some control over quality at the assembly level.
Use simpler structures which already been tested in the market and build experience over it could also be one way for example:
Straight & Reverse tuck end boxes, telescope boxes, wrap-around blank, Five-Panel Folder, Roll End Tray with Locking Cover, etc.
RESTRICT NUMBER OF PARTS
It is very necessary to have a limited number of parts in the design. As this directly impacts the cost and time taken to assemble. If there are too many parts then warehouse staff can show reluctance and this might lead to unnecessary conversations and revisions. There is a possibility of missing parts while bundling and is difficult to keep a quality check. This might also add to the inventory cost which is not advisable in the long run.
On the backhand, we should know the number of workers assigned to complete one order or are there at counters(in case of retailers). This keeps designers and engineers in sync how much time it will take to form one package. It is a good practice to develop 1:1 scale prototypes and clock it while forming. In this way, we will be able to understand how much time has gone to assemble one package and evaluate the design.
Too many parts of packaging can also overwhelm a consumer while unboxing. They might get on a guilt trip while disposing of the packaging that can lead to a bad experience.
PRE GLUED PARTS
The advantage of pre-glued packaging is that it is the fastest and the most efficient way to form the packaging. The gluing is done in the pre-assembly stage and is couriered in a collapsible format to the warehouse. The structure needs to just pop open to place to form the packaging. The only con of this is the additional gluing cost but it makes up for the time & speed in assembly. This is also helpful for retailers especially in food chains who have to pack speedily while there is a lot of crowd awaiting.
One of the most efficient shipper box locks is an auto bottom lock. It can take heavy loads and just needs to be popped open to place for formation.
REDUCE POST PROCESSING
Sometimes it is necessary to save packaging from external weather conditions & rigorous transit conditions. Hence, post-processing becomes very crucial in some packaging. While it is a crucial step we can avoid a number of post-processing steps and include it in the main design itself. Like providing tamper evidence in the main structure itself rather than providing tape or plastic sheet over it.
Most of the packaging uses shrink sleeves on top of packaging for barrier properties but it becomes an additional step after assembly. If this can be avoided in some packaging it will reduce a lot of energy and time. Though this advice can be given by your packaging consultant.
It is disheartening to see amazing designs fail at the execution stage. Though there is an abundance of scope to innovate we can keep a few pointers & challenges of the assembly line in our mind for smooth execution of the project. Designers & engineers can definitely make videos and prototypes to help them explain the design & formation to the warehouse staff where packaging is going to form. This does not mean we stop innovating but we can take one step more to keep the design intact at all stages and make sure it reaches to the consumer with the same impact as we have envisioned.
If you have any query or would like to discuss your packaging requirement, you can contact me at amitajain16@gmail.com
-Amita