Every packaging project we manufacture begins with structural design. Our in-house CAD team develops formats that protect the product, reduce material use and run efficiently on automated production lines, and every design is sampled before any tooling is ordered.
How a design comes together
- Brief. We take the product dimensions, weight and fragility, the shipping route and carrier limits, and any print or closure requirements.
- Structure. The team selects a FEFCO base style or develops a bespoke die-cut, laying the blank out for board efficiency.
- Sample. The design is cut on our digital flatbed as a white sample for fit, assembly and drop testing.
- Approval and tooling. Once signed off, production tooling is ordered and the specification is locked for repeat supply.
Value engineering
Design is where the biggest savings sit. Typical improvements on the programmes we take on include reducing blank size to lower board consumption, holding pack strength while moving to a lighter flute, and simplifying assembly so packs run faster on the bench.
Low-volume and custom runs
The digital flatbed also produces short custom runs where a production die is not justified, which lets a distributor trial a format with an end customer before committing to volume.
