The balancing act of packaging
Designing suitable packaging is a delicate balance of function, accessibility, product protection, user safety, marketing, and sustainability. Overemphasize one area, and the other areas suffer. For example, a package that provides maximum protection might require materials that are not recyclable, which causes sustainability to suffer.
This post examines the most common industrial packaging design mistakes and how to avoid them.
1. Not speaking with a materials specialist soon enough
The Mistake: Waiting until the end of the design process to consult an industrial designer or materials specialist.
Why it’s an issue: Your marketing team and product designer are experts in their fields. However, they may not know enough about packaging to avoid a problematic design feature of a package. Whether intended for the consumer or as a container to transport components between manufacturing partners, your package needs to be feasible to accomplish its goals.
The fix: A materials specialist can save you time and money by offering expert opinions on your package concept. Involve them in the process as soon as possible.
Learn more: Seven Ways Engineers Benefit from Working with a Material Specialist
2. Not considering the end user
The mistake: Function is king in industrial package design. Not considering the end user and the overall function of the package can lead to issues with marketing, safety, protection, and accessibility.
Why it’s a mistake: In retail, you must consider things like e-commerce requirements, shelf space, and the ability to stack goods. Additionally, if consumers find your package confusing or hard to open, it can directly affect sales. You must consider safety, ease of use, and compliance in industrial applications. Poor design can damage your brand’s reputation.
The fix: Take the time to think through your package’s primary goals. Focus groups or package testing may be a worthwhile investment.
3. Using the wrong packaging material
The mistake: Choosing the wrong material to suit the primary purposes of your package, usually to cut costs.
Why it’s a mistake: Each material has pros and cons, strengths and weaknesses. For example, if your package is meant to be kept outside for long periods, it must be weatherproof, and unwaxed cardboard would not be a great fit.
The fix: Speak with a materials specialist to choose the right material for the right job.
4. Wasteful packaging or ignoring sustainability practices
The mistake: Prioritizing other elements of industrial package design over sustainability.
Why it’s a mistake: Various studies estimate that between 60% and 80% of consumers are at least somewhat concerned about the sustainability of their purchases. One study shows that 30% of consumers are loyal to companies based on ethics. And waste, even in small amounts, leads to higher costs over time.
The fix: Balance your packaging’s core needs with sustainability factors like recyclability or reusability. Consider a minimal design that reduces overall materials and weight, leading to a lower carbon footprint.
5. Missing an opportunity for branding
The mistake: Not branding or designing messaging on customer-facing packages.
Why it’s a mistake: Even in transport, industrial packaging can be an opportunity for brand awareness. Creative designs or messages on pallet wraps or other packaging, especially in construction applications, can serve as mini billboards for your organization.
The fix: Investigate printed logos on different materials.
Learn more: Printed Stretch Film: 5 Questions You Should Ask
6. Not following regulations or standards
The mistake: Ignoring compliance guidelines.
Why it’s a mistake: The rules around packaging are in place to keep consumers safe. Combustible products need proper labeling, and wood materials (such as pallets) must be treated to prevent invasive insects or rodents. Cutting corners with compliance may save money in the short term, but it can be devastating in the long term, with consequences ranging from fines to loss of licensure.
The fix: Conduct regular audits to ensure your business complies with the latest regulations. Consult with packaging experts to ensure your operations are compliant before regulators inspect your facilities.
7. Improper storage
The mistake: Not monitoring, cleaning, or regulating storage areas.
Why it’s a mistake: Poor conditions can degrade the quality of your packaging materials. Excessive heat or cold can break down adhesives in tape, while overly humid conditions can spawn rot or mold.
The fix: Protect your packaging materials by routinely inspecting the HVAC and facilities management of storage areas and keeping all areas clean and tidy.
Also read: Leaning into Lean: Boosting Business Performance with Lean Manufacturing Techniques
8. Ignoring market trends
The mistake: Not paying attention to forces driving the packaging market.
Why it’s a mistake: Consumer preferences, legislation, policy changes, international events, and natural disasters can all affect the price of packaging materials and operations.
The fix: Keep current with the latest market trends by reading relevant publications and blogs, attending seminars, or speaking with your packaging partner.
Learn more: Packing Industry Trends to Watch in 2025
9. Choosing the wrong partner
The mistake: Not putting enough consideration into your packaging partner.
Why it’s a mistake: A packaging supplier enormously impacts your business. You want an experienced and empathetic partner who is as invested in your success as you are. Otherwise, you may experience any other mistakes discussed in this post.
The fix: Carefully consider your options and choose the best fit for your business objectives.
Adherex Packaging has decades of experience in the industry. With our deep expertise in materials and design for industrial packaging, you can trust that we’ll steer you in the right direction. Leverage our industry relationships to get the highest quality products at the most reasonable price.
Are you worried about making these or other mistakes? Get in touch to talk it through.
